An analytical transient cutting force model of high-speed ultrasonic vibration cutting

In the present study, an analytical transient cutting force model for high-speed ultrasonic vibration cutting has been developed. Micro-machining characteristics are figured out when both the tool nose round and round cutting edge are taken into consideration in the cutting mechanism. Four cutting zones (i.e., elastic recovery, plowing, shearing, and tool-chip friction) are proposed and analyzed to calculate the transient cutting force on each divided cross section in the normal direction of the cutting tool along the cutting edge. A non-free cutting coefficient is added to evaluate the influence of the tool shape on the cutting force compared to the orthogonal cutting model. Afterwards, transient cutting force and average cutting force are simultaneously measured. The results show that the shape and value of the transient cutting force correspond well with what was calculated using the proposed model, and the availability of the proposed model is verified by the cutting force shapes and values.