In-process modeling of dynamic tool-tip temperatures of a tunable vibration turning device operating at ultrasonic frequencies

The development of a model used to describe the mechanism by which vibration assisted machining reduces tool temperature is discussed, and correlations to resulting reduction in tool wear are presented. This model is applied to a newly developed ultrasonic, vibration assisted diamond turning device that allows for variation of vibration frequency and vibration amplitude via a direct drive actuator. It accommodates a wide range of vibration parameters, including vibration frequencies up to 40 kHz and amplitudes up to 8 μm, where the tool operates. The model uses the finite element method to predict cutting temperatures under conventional turning conditions (i.e., without vibration assistance). The results from the finite element analysis are then used in conjunction with a model developed for vibration assisted machining to predict the new temperature profiles. The modeling techniques and temperature histories for various vibration conditions are presented as well as experimental results that show the thermal advantages of applying tool vibration.