Abstract
The aim of this study is to investigate the cutting phenomenon under ultrasonic vibration-assisted
cutting condition. The vibrating cutting edge is considered to be cause of dynamic change of cutting force at
ultrasonic frequency. However many researchers have explained the effect of ultrasonic vibration-assisted cutting
by evaluating the time-averaged cutting force, because it is difficult to measure the dynamic cutting force by
using dynamometers. In this study, the instantaneous stress distribution on workpiece was visualized by photoelastic
method in combination of pulse laser emission synchronized with vibration of cutting edge. Orthogonal
cutting test was carried out at low cutting speed relative to vibration speed of insert. A constructed photographic
system divided the ultrasonic vibration period of 36.2 μs into 360 points and took one photograph frame at each
point. By counting the number of criteria pixels which images the cutting stress, the intermittent cutting condition
was evaluated. It was experimentally confirmed that the stress distribution under vibration-assisted condition
showed the periodical change synchronized with insert vibration. The intermittent cutting condition was affected
not only feed rate but also depth of cut. The theory of relative motion between blade and work is insufficient to
explain these results. Therefore remnants formed due to elastic deformation of the workpiece were examined.
The vibration cutting dramatically reduced the elastic deformation and the vibration amplitude had effect on the
amount of remnant thickness.
