Modeling and simulation of micro-groove topography on cylindrical surface by elliptical vibration-assisted turning

Micro-grooving, as a form of surface texturing, has a wide array of industrial applications. However, the majority of micro-grooving operations have been mainly done for flat surfaces. In this paper, ultrasonic elliptical vibration is used to assist micro-groove turning on cylindrical surfaces and model of micro-groove topography on cylindrical surface by elliptical vibration-assisted turning is investigated. First, elliptical vibration-assisted micro-groove generation process on cylindrical surface is analyzed by considering the geometry of tool and the cross-sectional area of chip in each vibration cycle. Then, the model of micro-groove topography on cylindrical surface is established by combining the tool tip arc curve and the ultrasonic elliptical vibration-assisted cutting locus curve. In the modeling process, the trajectory equation of tool tip arc curve in elliptical vibration process is obtained by sweeping tool tip arc curve along elliptical vibration locus. Surface topography equation of micro-groove considering the machining parameters and vibration parameters can be obtained based on the established trajectory equation of tool tip arc. Thus, model of micro-groove topography on cylindrical surface is constructed based on the Boolean operation between the cylindrical surface and the obtained surface topography equation of micro-groove. Finally, simulation algorithm of micro-groove generation process is proposed based on surface topography model of micro-groove on cylindrical surface in details. The influence of machining parameters and vibration parameters on micro-groove generation is analyzed and compared based on the established surface topography model and the proposed simulation algorithm. In order to validate the proposed surface topography model and simulation algorithm, a series of micro-groove cutting experiments under different machining conditions are performed to verify the predicted effect of the established simulation model. The results show that the simulation of the established micro-groove generation model correlates well with the experimental results.