FE Simulation of Linear and Elliptical Ultrasonic Vibrations in Turning of Inconel 718

Utilization of ultrasonic vibrations in turning operation is an advanced method to improve processing of materials. The aim of present study is to develop a finite element model in order to investigate the effect of ultrasonic vibrations on machinability factors in turning of Inconel 718. Conventional turning in addition of linear and elliptical ultrasonic assisted turning were simulated and effect of these processes on cutting forces, shear angle, chip thickness, sticky zone, and temperature distributed on tool rake face were analyzed. Besides, the experimental tests were conducted and the cutting forces have been measured to validate the simulation outputs. As a result, analysis of chip formation shows that the values of higher than 45 degree for shear angle is achieved when elliptical vibration is added to the cutting process. Furthermore, increase of shear angle coupled with decrease of temperature on tool rake face cause the sticky zone in tool-chip contact length to be reduced compared to the conventional turning. Moreover, the influence of cutting speed on tool-chip engagement time in ultrasonic assisted turning is simulated.

Turning simulation; Linear; Elliptical; Ultrasonic vibrations; Shear angle; Inconel 718.