Decrease of friction in tool–chip contact zone is a key subject in metal cutting operation. Therefore, effect of ultrasonic vibration in this area is analyzed by using experimental and simulation… Click to show full abstract
Decrease of friction in tool–chip contact zone is a key subject in metal cutting operation. Therefore, effect of ultrasonic vibration in this area is analyzed by using experimental and simulation methods. In this study, a theoretical model is firstly developed based on the shear friction model, and then sticking–sliding contact zones plus their contact lengths are defined in order to simulate conventional and ultrasonic-assisted turning. Accordingly, shear angle, sticky length, and cutting forces were measured in experiments as input parameters for the calculation of friction coefficients. As a result, intermittent contact of vibrated tool decreases the time of thermal conduction in tool–chip interface, resulting in a significant reduction in friction coefficient and contact length, particularly, in sticky region.
               
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