Investigation of ultrasonic mechanism and development of tool wear model in ultrasonic elliptic vibration assisted cutting of stainless steel

By analyzing the kinematics and dynamics of ultrasonic vibration under various conditions, the tool wear mechanism in Ultrasonic Elliptic Vibration-Assisted Cutting (UEVAC) were investigated. Two distinct mechanisms for mitigating tool wear emerge: In non-separated UEVAC, the pivotal factor is the reduction of material yield stress through the acoustic softening effect. Conversely, in separated UEVAC, tool wear reduction is attributed to the decrease in average contact stress via stress superposition and the hammer effect. These findings highlight the effectiveness of aligning ultrasonic energy field action times and intensity to reduce stainless steel tool wear rates in non-separated UEVAC. Furthermore, the proposed tool wear model demonstrates robust reliability for separated UEVAC processes.