Vibration cutting belongs to a type of CNC machining, which has advantages such as low cutting force, low cutting temperature, easy removal of chips, and extended tool life.
If the vibration parameters are selected properly, the tool life can generally be extended by several to several tens of times, which is difficult to achieve in difficult to machine materials and machining operations. The ultrasonic vibration cutting test using hard alloy cutting tools on stainless steel shows that the tool life is 20 times longer than traditional cutting methods. Extending tool life helps to save tool materials, reduce auxiliary time, lower the processing cost of precision mechanical parts, improve production efficiency, and improve machining quality.
During normal cutting, the blade is continuously pressed against the slope of the tool, forming a high-temperature and high-pressure zone. The cutting fluid is difficult to enter the cutting zone and can only play an indirect cooling role around the tool. In vibration cutting, when the cutting is intermittent and the tool separates from the precision components, the cutting fluid cools and lubricates the tool tip. Especially in ultrasonic vibration cutting, the cavitation caused by ultrasonic vibration emulsifies the cutting fluid, forming uniform emulsified particles. On the other hand, cutting fluid can easily penetrate material cracks, further improving the effectiveness of cutting fluid use and chip removal conditions, thereby improving the machining quality of precision mechanical parts.
During the vibration cutting process, the tool vibrates in a sinusoidal pattern, forming small tool marks on the machining surface, similar to the patterned pattern formed during the second machining. Numerous patterns are evenly distributed on the machining surface of precision mechanical parts, which is conducive to forming a thick oil film during operation and improving the wear resistance of sliding friction. The residual stress in vibration cutting is very low, the machining conversion layer is shallow, and the machining deformation near the cutting edge is very small. Corrosion and cutting tests have shown that the wear resistance and corrosion resistance of the workpiece surface processed by vibration cutting are close enough to the ground, which can ensure the machining accuracy of precision mechanical parts.
