High-speed precision interrupted ultrasonic vibration cutting method

A high-speed precision interrupted ultrasonic vibration cutting method, comprising steps of:

• (1) installing an ultrasonic vibration apparatus on a machine tool, and stimulating a cutting tool to generate a transverse vibration or a vibration with a transverse component, wherein:
• through combining different vibration types and machining process types, varieties of machining processes are able to be realized;
• (2) realizing an interrupt cutting processing by setting cutting parameters and vibration parameters to satisfy interrupted cutting conditions and periodically separating the cutting tool from a finished surface profile of a workpiece;
• and
• (3) turning on the ultrasonic vibration apparatus and the machine tool, and starting a high-speed precision interrupted ultrasonic vibration cutting process;
• wherein:
• high-speed interrupted ultrasonic vibration cutting is able to be realized through the above steps during machining of difficult-to-machine materials in aviation and aerospace fields;
• a cutting speed is enhanced significantly, which exceeds a critical cutting speed of a conventional ultrasonic vibration cutting method and an elliptical ultrasonic vibration cutting method and even a high speed range of a traditional cutting method;
• besides, beneficial effects of cutting force and cutting temperature reductions, tool life prolonging, machining cost save, and surface quality and machining accuracy improvements are all obtained at the same time;
• the interrupted cutting condition in the step (2) refers to a formula as listed of:
• {
• Δ
• ≤
• 2
• ⁢
• ⁢
• A
• 2
• ⁢
• ⁢
• arcsin
• ⁡
• (
• Δ
• /
• 2
• ⁢
• ⁢
• A
• )
• ≤
• ϕ
• ≤
• 2
• ⁢
• π
• -
• 2
• ⁢
• ⁢
• arcsin
• ⁡
• (
• Δ
• /
• 2
• ⁢
• ⁢
• A
• )
• ,
• wherein:
• Δ is a center line offset value of two adjacent feed tool paths, which is related to the cutting parameters of feedrate and depth of cut, and determined according to a specific machining process and vibration types;
• ϕ is a phase difference of the two adjacent feed tool paths, which is related to the vibration parameters of tool vibration frequency and workpiece or tool rotatory speed, and determined according to the specific machining process and the vibration types;
• and A is a tool vibration amplitude.