An Investigation on the Effect of Vibrational Parameters on Tool Temperature in Ultrasonic Assisted Turning

In recent years, demand for increasing quality and tool life and for decreasing machining force has led to the use of vibratory tool instead of fixed one in the conventional cutting. Tool wear as one of the most important economical parameters, must be considered. As will be shown in the present paper, heat as the most important parameter can decrease tool life significantly. Thermal analysis of tool tip temperature in ultrasonic assisted turning (UAT) is very complex because of the high frequency fluctuations in the nature of this process. In this paper, ABAQUS finite element software has been used for the thermal analysis of orthogonal turning of Al7075-T6 to study the effect of machining parameters (cutting speed and feed rate) and vibration parameters (amplitude and frequency) on the tool tip temperature in UAT. A comparison has also been made with the conventional turning (CT) temperature. It has been shown that, when the tool engages with the work piece, the cutting tool temperature increases. This increase in UAT is more obvious than the temperature decrease occurring when the cutting tool separates from the work piece. Moreover, with increasing vibration amplitude, the maximum tool temperature also increases. In constant vibration speed, low amplitude and high frequency should be used to achieve minimum temperature.