Modeling and analysis of the chip formation and transient cutting force during elliptical vibration cutting process

In traditional diamond cutting, the cutting force is usually large and it will affect tool life and machining quality. Elliptical vibration cutting (EVC) as one of the ultra-precision machining technologies has a lot of advantages, such as reduces cutting force, extend tool life and so on. It’s difficult to predict the transient cutting force of EVC due to its unique elliptical motion trajectory. Study on chip formation will helpfully to predict cutting force. The geometric feature of chip has important effects on cutting force, however, few scholars have studied the chip formation. In order to investigate the time-varying cutting force of EVC, the geometric feature model of chip is established based on analysis of chip formation, and the effects of cutting parameters on the geometric feature of chip are analyzed. To predict transient force quickly and effectively, the geometric feature of chip is introduced into the cutting force model. The calculated results show that the error between the predicted cutting force in this paper and that in the literature is less than 2%, which proves its feasibility.