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Explore the integration of Vibration-Assisted Machining (VAM) with Finite Element Analysis (FEA) software, examining tool characteristics, cutting speeds, frequencies, thermal effects, and future prospects in machining technology.
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Numerical Simulations of Vibration Assisted Machining John Patten and Andre Williams Manufacturing Research Center Western Michigan University, Kalamazoo MI
Motivation of Project • UNCC: VAM Diamond Turning of Steel • Tool • 0.0005 mm cutting edge radius • Zero degree rake angle • 10 degree clearance angle • Machining • Cutting speed 0.175 m/s • Depth of cut: 0.120 mm • Feed: 0.02 mm • VAM • Amplitude: 0.008 mm (8 micrometers, μm) • Frequency: 10,000 Hz
Development of FEA Software • Third Wave Systems, Inc. • WMU worked with TWS to incorporate a VAM module capability into their commercial machining simulation software, AdvantEdge • Interest in simulating work by Dow et al. at the PEC @ NCSU: SiC
Basic Model Parameters • Base Case: Diamond Tool, Steel: 12L14 • Tool: • Cutting edge radius: 0.002 (0.001) [0.0005] mm • Rake Angle: zero degrees • Clearance Angle: 10 degrees • Cutting Speed: 1 m/s (0.5 and 0.25) [0.175] • Feed: 0.02 mm (uncut chip thickness) • VAM: 10,000 Hz (0, 2, 4, 8 μm amplitude) • Thermal Model/Conditions: On and Off
FEA Simulation results • Variables • Amplitude • Speed • Output • Temperature • Forces
.5 m/s speed VAM Simulation with Thermal ON and.002 amplitude
.25 m/s speed VAM Simulation with Thermal ON and .008 amplitude
Future Work • Silicon Carbide: SiC (CVD coated) • Aluminum Titanium Carbide: AlTiC • Cutting Fluids • Thermal effects • Friction effects • Chip formation and breakage • Tool Geometry • Tool Wear
Acknowledgements • NSF • TWS • Jerry Jacob (WMU)