Numerical Simulations of Vibration Assisted Machining

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Numerical Simulations of Vibration Assisted
Machining

• John Patten and Andre Williams
• Manufacturing Research Center
• Western Michigan University, Kalamazoo MI

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Motivation of Project

• UNCC VAM Diamond Turning of Steel
• Tool
• 0.0005 mm cutting edge radius
• Zero degree rake angle
• 10 degree clearance angle
• Machining
• Cutting speed 0.175 m/s
• Depth of cut 0.120 mm
• Feed 0.02 mm
• VAM
• Amplitude 0.008 mm (8 micrometers, µm)
• Frequency 10,000 Hz

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Development of FEA Software

• Third Wave Systems, Inc.
• WMU worked with TWS to incorporate a VAM module
  capability into their commercial machining
  simulation software, AdvantEdge
• Interest in simulating work by Dow et al. at the
  PEC _at_ NCSU SiC

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Basic Model Parameters

• Base Case Diamond Tool, Steel 12L14
• Tool
• Cutting edge radius 0.002 (0.001) 0.0005 mm
• Rake Angle zero degrees
• Clearance Angle 10 degrees
• Cutting Speed 1 m/s (0.5 and 0.25) 0.175
• Feed 0.02 mm (uncut chip thickness)
• VAM 10,000 Hz (0, 2, 4, 8 µm amplitude)
• Thermal Model/Conditions On and Off

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Simulated Process Variables
Amplitude (µm) Speeds m/s Thermal Model
0 1.0 and 0.5 On/off
2 1.0 and 0.5 On/off
4 1.0 and 0.5 On/off
8 1.0, 0.5 and 0.25 On/off
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FEA Simulation results

• Variables
• Amplitude
• Speed
• Output
• Temperature
• Forces

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1 m/s VAM Simulation with Thermal ON and 0
Amplitude
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.5 m/s VAM Simulation with Thermal ON and 0
Amplitude
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.5 m/s speed VAM Simulation with Thermal ON
and.002 amplitude
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1 m/s VAM Simulation with Thermal ON and 0.008
Amplitude
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.25 m/s speed VAM Simulation with Thermal ON and
.008 amplitude
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VAM Simulation with Thermal ON, .004 Amplitude,
and 1 m/s
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Tool Temperature
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Maximum Workpiece Temperature
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Work piece Temperature
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Thermal ModelOn/Off ComparisonAverage/Dynamometer
Force
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Cutting Force, 4 micrometer vib. amp., 1 m/s
cutting speed
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Averaged Peak Cutting Forces
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Cutting Force Vs. Amplitude
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Cutting Force Vs. Cutting Speed
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Cutting Force, Amplitude Speed
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Future Work

• Silicon Carbide SiC (CVD coated)
• Aluminum Titanium Carbide AlTiC
• Cutting Fluids
• Thermal effects
• Friction effects
• Chip formation and breakage
• Tool Geometry
• Tool Wear

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Acknowledgements

• NSF
• TWS
• Jerry Jacob (WMU)