Modulated orthogonal cutting system realized by piezo stack actuation and linear guide coupling

Modulation-assisted machining (MAM) employs low-frequency feed-direction tool vibration to enhance conventionally continuous cutting processes such as turning, drilling, and boring operations. The development of a suitable tool vibration system is critical for the success of MAM. In this paper, a tool vibration system realized by using piezo stack actuation and linear guide coupling was designed and constructed. The performance of the system was evaluated by conducting orthogonal tube face turning tests on AISI 1045 steel using a range of cutting and modulation conditions. Cutting forces and tool vibration displacement were measured and analyzed. A mechanistic force model based on the variable uncut chip thickness was used to predict the variable primary cutting and feed forces in MAM which showed good agreement with the measured forces. Furthermore, It was found that the vibration amplitude with cutting was reduced when compared to the vibration amplitude without cutting. The reduction in vibration amplitude was predictable as it depends on the feed force and the stiffness of the system. The results indicate good control ability of the tool vibration system across a wide range of cutting and modulation conditions.