Effect of tool vibration on tool wear in ultrasonic vibration cutting

Theoretical and experimental studies on the effect of tool vibration on tool wear in ultrasonic vibration cutting are presented. Analyses are given on the mechanics of ultrasonic vibration cutting, from which the relationships between the vibration and machining parameters are described. The special mechanisms of tool wear in ultrasonic vibration cutting are discussed using the analyses. Experimental tests for tool wear in cutting with and without the vibration at various cutting conditions are conducted based on the analyses. Compared to conventional cutting, it is found that in ultrasonic vibration cutting the tool crater wear is much less, but the tool flank wear is larger. The effect of tool ultrasonic vibration on tool wear is more significant when a water-based coolant is applied to the cutting region.