Development and Experiment of a Novel Vibration-assisted Cutting Apparatus

Abstract

Vibration-assisted cutting as one of specially typical precision non-conventional machining methods, recently, has aroused lots of scholars and science researchers interests, especially in hard and brittle material cutting with a significant challenge. The objective of present study develops a novel apparatus which combines mechanical and control design, a series of cutting experiments conducted on Al 7075 alloy that defined as one of high strength alloy materials appliance in lots of industries field to investigate the feasibility and reliability of the appliance. In present paper, a mechanical model of vibration- assisted cutting apparatus was designed and than evaluated by off-line test analysis. The novel apparatus can work at below 124 Hz with maximum stroke 27.285µm. Fuzzy PID was preliminary introduced into vibration-assisted cutting apparatus control strategy. Programs were established based on LabVIEW software and then downloaded into NI Compact 9033 controller in order to control vibration-assisted cutting apparatus. By compared with three strategies each other, the tracking error of fuzzy strategy increased 11.2 times that of fuzzy PID, at the same time, PID strategy oscillation amplitude increased 5.3 times that of fuzzy PID. A series of cutting experiments were conducted on the plane and freeform surface deforming. The validity and availability of vibration-assisted cutting apparatus were conducted in experiments.