Effect of cutting and vibration parameters on the cutting performance of 7075-T651 aluminum alloy by ultrasonic vibration

The purpose of this study was to investigate the effects of the cutting and vibration parameters on the machining performance of 7075-T651 aluminum alloy in an unidirectional ultrasonic vibration cutting. Simulation experiments were performed using the AdvantEdge finite element analysis software. The results showed that as the cutting speed and feed rate increased, the cutting force and cutting temperature of the ultrasonic vibrations in the x- and y-directions increased. As the amplitude and frequency increased, they decreased accordingly. The highest temperatures of the rake and relief of the tool were located 0.01–0.02 mm from the cutting edge. With the change in the cutting and vibration parameters, the residual stress curve had a “spoon-shaped” distribution. When the cutting parameters were increased, the magnitude of the residual stress and the depth of the layer increased to a certain extent. With the increase in the vibration parameters, the change in the residual stress value of the ultrasonic vibration in the x direction was small, whereas the residual stress value of the ultrasonic vibration in the y direction increased accordingly. y-direction ultrasonic vibration and conventional cutting experiments were performed on the workpiece. The simulation values of the y-direction ultrasonic vibration cutting agreed well with the experimental values. At the same time, compared with conventional cutting, the ultrasonic vibration cutting exhibited a greatly reduced cutting force and cutting temperature.