Effect of ultrasonic vibration on frictional behavior of tool-chip interface: Finite element analysis and experimental study

Ultrasonic-assisted machining is an advanced method which allows significant improvements in processing of materials. In this study, a finite element model is developed to study the effect of ultrasonic vibration on machinability of AISI 304 stainless steel in which the results are compared with conventional cutting process. A pneumatic quick-stop device and an optical microscope are applied to validate the simulation results by measuring shear angle and sticky region experimentally. As a result, the analysis of heat generation in primary and secondary deformation zones shows that temperature increases in the primary zone when ultrasonic vibration is used, while a significant reduction in temperature is seen in the tool-chip contact zone. This area is considerably effective on the length of sticky region. Moreover, the influence of cutting speed and feed rate on tool-chip engagement time is investigated by the analysis of cutting force profile.