Mechanism of a novel parallel ultrasonic vibration-assisted cutting system for high performance machining

Titanium alloy slender shafts have wide application on the aerospace, automotive and medical devices. However, they are prone to bending deformation during cutting process due to their low rigidity, resulting in poor machining accuracy and efficiency. A novel parallel ultrasonic vibration-assisted cutting (PUVC) system is proposed using two tools to simultaneously cut the workpiece and applying tangential ultrasonic vibration contributing to overcome above challenges. The main concept, motion trajectory and separation characteristics of PUVC system are analyzed. An analytical model for PUVC that integrating cutting intersection mode, chip geometry model, cutting force model and workpiece deflection feedback model is established. On this basis, the influencing mechanism of cutting force, diameter error and temperature of PUVC is explored under different cutting modes, ultrasonic parameters, tool parameters and cutting parameters. Furthermore, an experimental validation is performed to verify the proposed model's accuracy and methodological efficacy, thereby establishing a reliable foundation for implementing this approach in high-precision manufacturing industries applications.