FEM and Experimental Investigation of Cutting Force During UAT Using Multicoated Inserts

This paper presents finite-element modeling and experimental study of the main cutting force in ultrasonic assisted turning (UAT) of Aerospace Aluminum using multicoated carbide inserts. At first, mathematical models were developed to investigate the effects of tool coating, rake angle, cutting speed, and feed rate on the friction coefficient. Then, with respect to the kinematics of the process, the cutting velocity model is presented. This velocity model is used in combination with mathematical models to define the friction coefficient during UAT. The mentioned frictional model is used to write a user subroutine to incorporate the effect of friction coefficient as a function of cutting parameters in the finite-element software Abaqus. Then, 2D finite-element modeling (FEM) models are developed for simulation of conventional turning (CT) and UAT with multilayer cutting tools. The models are used to investigate the effect of vibration amplitude, work velocity, feed rate, rake angle, and multicoated tool on the main cutting force during both CT and UAT. Finally, the results of FEM are compared with experimental measurements of the main cutting force. The results show that UAT is able to lower the main cutting force, by about 29%, in low feed rates (approximate to 0.14mm/rev), with vibration amplitude of approximate to 10 mu m and work velocity of approximate to 0.5m/s.