Design of an ultrasonic elliptical vibration cutting tool based on an eccentric cone.

Ultrasonic elliptical vibration cutting (UEVC) has been successfully applied to precision machining of difficult-to-machine materials with its advantages of low machined surface roughness and low tool wear. In this study, an eccentric cone UEVC tool is proposed based on the mechanical vibration theory, with the idea of combining longitudinal vibration and bending vibration. The preliminary dimensions of the UEVC tool are obtained by theoretical calculations. Then, the dimensions of the tool are optimized through finite element analysis (FEA) to meet the requirements of vibration modes and resonant frequencies. Finally, a prototype of the eccentric cone UEVC tool is developed, and the vibration performance tests and cutting experiments are conducted on the designed tool to verify its cutting trajectory and cutting performance. According to the results, the new developed eccentric cone UEVC tool can achieve the elliptical vibration trajectory at the tool tip; the resonant frequency of the tool is 28019 Hz; and the longitudinal and the bending amplitude are 6.2 μm and 4.9 μm, respectively. The new developed eccentric cone UEVC tool can obtain workpieces with the surface roughness about 0.337 μm and reduced the tool wear. [ABSTRACT FROM AUTHOR]