Mechanism of a high performance and energy efficiency parallel ultrasonic vibration-assisted cutting

Yupeng Long, Wei Cai, Hongxiang Yin, Zifan Liu, Shun Jia, Kee-hung Lai and Marian Wiercigroch

Energy, 2025, vol. 326, issue C

Abstract: Shafts made from titanium have been widely used in aerospace, medical and automobile manufacturing field fields. Due to their low thermal conductivity, low stiffness and high energy consumption, they are easy to deform during cutting, resulting in low machining performance, production and energy efficiency. A new high performance and energy efficiency process, Parallel Ultrasonic Vibration-assisted Cutting (PUVC), is proposed in this work to overcome above challenges. This paper introduces two important cutting modes of PUVC shared cutting surfaces (SCS) and non-shared cutting surfaces (NSC), where the NSC mode improves the cutting efficiency and decreases the energy consumption. Through analysis of PUVC's main cutting force, cutting temperature and workpiece stress field, the cutting mechanism of PUVC is studied. Furthermore, an experimental validation is conducted with respect to the cutting temperature and surface residual stresses, showing strong correlations with modelled predictions. Besides, the PUVC and Single-tool Ultrasonic Vibration-assisted Cutting (SUVC) are compared and analyzed with different length-diameter ratios to asses the advantages of PUVC for slender shafts. Experiments and simulations have shown that the SCS model has better fit than the NCS model. PUVC has significant advantages over workpieces with large aspect ratios. When the aspect ratio is 5, the temperature can be reduced by up to 30 %, and the diameter error can be as low as 0.036 mm. Compared with SUVC, PUVC has lower power consumption (11 %–18 %), but dual tool machining increases residual stress.

Keywords: Energy efficiency; High performance; Ultrasonic vibration; Cutting; Titanium alloy (search for similar items in EconPapers)
Date: 2025
References: Add references at CitEc
Citations:

Downloads: (external link)
http://www.sciencedirect.com/science/article/pii/S0360544225018869
Full text for ScienceDirect subscribers only

Related works:
This item may be available elsewhere in EconPapers: Search for items with the same title.

Export reference: BibTeX RIS (EndNote, ProCite, RefMan) HTML/Text

Persistent link: https://EconPapers.repec.org/RePEc:eee:energy:v:326:y:2025:i:c:s0360544225018869

DOI: 10.1016/j.energy.2025.136244

Access Statistics for this article

Energy is currently edited by Henrik Lund and Mark J. Kaiser

More articles in Energy from Elsevier
Bibliographic data for series maintained by Catherine Liu ().