Experimental Investigation and Finite Difference Modeling of Cutting Tool Temperature Distribution During Ultrasonically Assisted Turning

This paper summarizes the experimental and numerical simulations of 2D temperature fields on the chip and cutting tool during ultrasonic assisted turning of AISI 4140 hardened steel using carbide inserts. To achieve this goal, the finite difference method is used to develop a numerical model in order to predict cutting tool’s temperature during ultrasonic assisted turning. First, finite difference method is used to develop a predictive model of cutting tool’s temperature in case of conventional turning and then the analysis results are used in combination with the model developed for ultrasonic assisted turning to predict cutting temperature profiles during this process. Finally, finite difference-based simulation results are validated with experimental measurements of temperatures from ultrasonic assisted turning tests using thermocouple technique. Using the analysis results, the effect of machining and vibrational parameters (cutting speed, feed rate, and vibration amplitude) can be easily studied on ultrasonic assisted turning cutting temperatures. The results show that ultrasonic assisted turning is able to lower the maximum cutting temperature in the cutting tool, about 37%, in low feed rates (≈0.11 mm/ rev), with a vibration amplitude of (≈10 .m) and work velocity of (≈30 m/min).