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Development of a low-frequency vibration-assisted
turning device for nickel-based alloy
Weichao Shi ( shiweichao@xaut.edu.cn )
Xi'an University of Technology
JianMing Zheng
LingJian Zhu
Ting Chen
ZhangShuai Jing
Chao Peng
Rong Xue
Qi Li
Research Article
Keywords: Nickel-based alloy, Low-frequency vibration-assisted turning, Chip separation conditions,
Adjustable dual eccentric mechanism, Cutting parameters
Posted Date: October 18th, 2023
DOI: https://doi.org/10.21203/rs.3.rs-3420132/v1
License: This work is licensed under a Creative Commons Attribution 4.0 International License.
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Development of a low-frequency vibration-assisted turning
device for nickel-based alloy
WeiChao SHI, JianMing ZHENG, LingJian ZHU, Ting CHEN, ZhangShuai
JING, Chao PENG, Rong XUE and Qi LI
School of Mechanical and Instrument Engineering
Xi’an University of Technology
5 South Jinhua Road
Xi’an, Shaanxi, China 710048
{shiweichao@xaut.edu.cn; zjm@xaut.edu.cn; 649244966@qq.com;
1191208472@qq.com; 1220211006@stu.xaut.edu.cn; 372715776@qq.com;
3168827191@qq.com; 875420187@qq.com}
Abstract ：As a typical difficult-to-machine material which is widely used in
aerospace and aviation field, the high quality and efficient machining of nickel-based
alloys has always been the hotspot in mechanical machining. However, the problem
of force and heat concentrations can reduce the machining stability of nickel-based
alloys, leading to tool wear and work hardening, seriously affecting the flow direction
and fracture of chips. Therefore, a novel low-frequency vibration-assisted turning
device is developed by using adjustable dual eccentric mechanism in this paper. The
chip separation conditions of low-frequency vibration turning is analyzed. The
relationship between cutting parameters and cutting force, cutting temperature, tool
wear, workpiece surface morphology, and tool life was studied through experiments.
The experimental results demonstrate that the low-frequency vibration-assisted
turning device can effectively suppress cutting force fluctuations, reduce cutting
temperature, delay tool wear speed, improve surface quality, and increase tool life,
meeting the high-quality and efficient machining requirements of nickel-based alloys.
The research results will provide theoretical support for the problem of chip breakage
in difficult to machine materials and the study of low-frequency vibration-assisted
cutting technology.
Keywords: Nickel-based alloy; Low-frequency vibration-assisted turning; Chip
separation conditions; Adjustable dual eccentric mechanism; Cutting parameters
1 Introduction
Nickel-based alloy materials have a range of advantages, such as high strength, high
temperature resistance, and corrosion resistance, enabling engines to withstand
extremely high temperatures and mechanical stresses, and are widely used in the
aerospace industry[1-3]. However, the high elongation and low thermal conductivity
of nickel-based alloy led to significant plastic deformation resistance and high cutting
temperature during the machining, which is prone to tool sticking, resulting in tool
wear and work hardening, affecting chip flow direction and fracture[4-7]. Therefore,
automatic chip breakage during the machining of nickel-based alloy is a critical factor
that restricts high-quality and efficient processing.
Vibration cutting mainly involves applying a regular vibration to the cutting tool,
changing the direction and magnitude of cutting force during the machining, thereby
controlling the size and shape of chips, improving cutting efficiency and processing
quality[8-10]. Compared with traditional cutting, vibration cutting has great potential
in reducing cutting temperature, extending tool life, and improving machining
quality[11-13]. According to the vibration frequency, vibration cutting is mainly
divided into low-frequency vibration cutting and ultrasonic vibration cutting. Among
them, ultrasonic vibration cutting has significant effects in processing flexible and
brittle materials, but the vibration amplitude of a few micrometers limits the
processing efficiency [14-15]. Under appropriate parameters of processing and
vibration, low-frequency vibration cutting can process high hardness materials, with
advantages such as good cutting effect, high stability, and strong chip breaking
performance.
Laporte et al. proposed a low frequency vibration cutting device that combines an
undulated ring with a flat ring, utilized the profile of the undulated ring generates
axial motion of the cutting tool, and the amplitude adjustment method was relatively
complex[16]. Jiao Feng et al. developed a low-frequency vibration-assisted drilling
device by using a ring flexure hinge as the elastic recovery mechanism, which could
realize the axial low-frequency vibration with constant frequency-to-rotation ratio and
amplitude stepless adjustment, and the device presented good working stability under
no-load and load conditions[17]. Hussein et al. conducted a study on the machining of
carbon fiber-reinforced polymers and Ti6Al4V alloy stacked materials using
low-frequency vibration-assisted drilling device, and analyzed the effects of cutting
speed, feed rate, modulation amplitude, and modulation frequency on the machining
quality[18]. Maroju et al. studied the mechanics of orthogonal turning with
low-frequency vibration assistance, and predicted the cutting force and temperature
during the machining process through finite element simulation, the experiment
showed that LVAT iis effective in reducing cutting forces, effective stresses, and
cutting temperature[19]. Thus, most low-frequency vibration-assisted cutting devices
use mechanical modes. Meanwhile, the cam mechanism, eccentric wheel mechanism,
and crank slider mechanism are often used in the vibration device, which can easily
lead to inconvenient amplitude adjustment, poor amplitude stability, and weak process
system stiffness. Therefore, the application of mechanical low-frequency vibration
cutting technology is limited[20-21].
To achieve high-quality and efficient machining of nickel-based alloys, a
low-frequency vibration-assisted turning（LFVAT）device for nickel-based alloys was
developed in this study, using an adjustable dual eccentric mechanism. The chip
separation conditions of low-frequency vibration cutting were studied. Comparative
experiments with conventional cutting were conducted to investigate the changes
rules of cutting force, cutting temperature, tool wear process, and workpiece surface
quality. The research results of this paper will provide theoretical support for the
problem of chip breakage in difficult to machine materials and the study of
low-frequency vibration-assisted cutting technology.
2 Working principle and separation conditions of LFVAT device
2.1 Working principle of LFVAT device
Low-frequency vibration turning is the application of additional axial vibration to the
tool or workpiece on the basis of conventional turning. The low-frequency
vibration-assisted turning device mainly consists of vibration generator, vibrating tool
rod, handlebody, and clamping block, as shown in Fig.1.
Motor
Eccentric shaft
Eccentric sleeve Swinging sleeve
Steel ball
Vibration generator
Vibrating tool rod
Handlebody Clamping block
Fig.1 Composition of the low-frequency vibration-assisted turning device
The vibration generator determines the amplitude and frequency rotation ratio of
the device, which is mainly composed of the motor, eccentric shaft, eccentric sleeve
swinging sleeve and steel ball. Among them, the motor spindle, eccentric shaft and
eccentric sleeve form the dual eccentric mechanism, and the matching relationship is
shown in Fig.2. O is the center of the motor spindle, O1 is the geometric center of the
eccentric sleeve, O2 is the geometric center of the eccentric shaft, e1 and e2 are the
eccentric distance of the eccentric shaft and the eccentric sleeve respectively. The
angle between the eccentric distance e1 and e2 is the misalignment angle α.
O1
O2
O
e1
e2
α
A
Eccentric shaft
Eccentric sleeve
Motor spindle
Fig.2 The matching relationship of dual eccentric mechanism
Therefore, the amplitude of the LFVAT can be expressed as:
22
1 2 1 2
2 cosA e e e e
= + −
（1）
According to equation (1), the misalignment angle α is the main factor that changes
the amplitude of LFVAT. The eccentric shaft is equipped with radial through-holes,
and through-holes with different angles are set along the radial direction of the
eccentric sleeve too. Therefore, different misalignment angles can be obtained by
matching radial through-holes of the eccentric shaft and eccentric sleeve, making
amplitude adjustment convenient. To meet production requirements, the amplitude of
LFVAT is set to five gears adjustment, and the relationship between the misalignment
angle α and the amplitude A is shown in Table 1.
Table 1. Correspondence between the misalignment angle and the amplitude
Misalignment angle
0
30
60
98
180
Amplitude
0
0.05
0.1
0.15
0.2
One end of the vibrating tool rod is connected to the swinging sleeve, and the other
end is fixedly connected to the tool. Therefore, the vibrating tool holder can transmit
the reciprocating linear motion of the swinging sleeve to the tool, ensuring that the
tool vibrates along the axial.
The clamping block is used to fix the LFVAT on the lathe tool holder, which can
avoid the deformation of the handlebody under clamping force and affect the
vibration transmission of the vibrating tool holder.
The LFVAT device can install on the lathe tool holder. Loosen the tightening screw
to adjust the misalignment angle between the eccentric shaft and the eccentric sleeve.
Under the action of tightening the screws and the preload of the steel ball, the
eccentric sleeve is tightly connected to the eccentric shaft. The eccentric shaft and
eccentric sleeve rotate with the motor spindle, and the eccentric sleeve drives the
swinging sleeve to undergo reciprocating linear motion. Under the action of the
vibrating tool rod, the reciprocating linear motion of the swinging sleeve is
transmitted to the tool, and the tool completes axial vibration. Therefore, the LFVAT
device can achieve tool axial vibration, and the vibration frequency and amplitude
depend on the motor operating frequency and misalignment angle respectively.
2.2 Separation conditions of LFVAT device
Fig.3 is schematic diagram of low-frequency vibration-assisted turning, z is the
spindle direction, n is the spindle speed, F is the tool feed rate, ap is the cutting depth,
fw is the axial vibration frequency of the tool, A is the amplitude, and t is the motion
time.
z
nap
FP
O
θ
r
Fig.3 The schematic diagram of low-frequency vibration-assisted turning
Therefore, the motion equation of any point P（r, θ, z） on the tool can be expressed
as:
( )
260
sin 2 60
p
r R a
nt
n
z A f t F t
=−
=
=+
（2）
Where, R is the radius of the unprocessed part of the workpiece, θ is the angular
displacement of the workpiece.
According to the relationship between angular displacement and time parameters
in equation (2), the motion equation of any point P on the tool can also be expressed
as:
( )
60
sin 2
fF
zA n
=+
（3）
In equation (3), the ratio of the axial vibration frequency of the tool to the spindle
speed is defined as the frequency rotation ratio:
60
f
fki
n
= = +
（4）
Where, k represents the integer part of the frequency rotation ratio, and i represents
the decimal part of the frequency rotation ratio. Usually, the minimum period of sine
function is 2π. Therefore, the decimal part of the frequency rotation ratio can
determine the degree of misalignment of adjacent cycle tool motion trajectories.
Fig.4 shows the motion trajectory of the tool with angular displacement, and it can
be seen that the tool space trajectory and instantaneous cutting thickness exhibit
periodic changes during the vibration turning process. Therefore, under the
appropriate parameter conditions, the motion trajectories of adjacent two circles can
overlap, meaning that the tool and workpiece will have a separation effect.
0.8 1.0 1.2
-50
50
0.6
-0.2 00.2 0.4
-40
0
-20
0
-20
-40
Z/μm
Y/μm
X/μm
Fig. 4 The motion trajectory of the low-frequency vibration turning tool
Then the motion trajectory equations of any point on the tool in adjacent periods
are:
( )
( )
( )
( )
1
sin 2
sin 2 2
2
Nf
N f
F
zA
F
zA
+
=+
= + + +
（5）
Where, N represents the tool cutting in the Nth cycle.
To ensure the separation effect of the tool and the workpiece, the motion
trajectories of adjacent cycles must have intersections. Therefore, the separation
conditions of vibration cutting can be determined by calculating the continuous
cutting conditions. The difference function between two adjacent periodic trajectories
can be written as:
( )
( )
( )
( )
( )
( )
( ) ( )
1, 1
sin 2 2 sin
22
2 sin cos
2 sin cos 2
N N N N
f
ff
ff
f
z z z
FF
AA
FA
F A f t
++
=
= + + + −
−
−
= + +
= + +
（6）
Then the condition of continuous cutting is that equation (6) is always greater than
zero, that is, it satisfies
1, 0
NN
z+
＞
（7）
Equation (6) takes the first order partial derivative of the time parameter t, and
makes it equal to zero, and finds the extreme point of the function:
( ) ( )
1, 4 sin sin 2
N
ff
N
zAf
tft
+
−+=
（8）
Therefore, there are two situations in solving equation (8):
(1) When
( )
sin 0
f
=
, it can be seen that ωf =k, i=0, substituting into equation
(7):
1, 0
NN
zF
+
=
（9）
Under the condition that the frequency rotation ratio is taken as an integer,
equation (6) is always greater than zero, and the machining is always continuous.
(2) When
( )
sin 2 0
f
ft
+=
, it can be seen that:
22
f
f t M
+=
（10）
Substituting equations (6) and (7):
( )
( )
( )
1, 2 sin cos 2
2 sin
2 sin ( )
2 sin( ) 0
N fN
f
z F A M
FA
F A k i
FAi
+
= +
=+
= + +
= −
（11）
By solving complementary set of equations (10) and (12), the separation conditions
for low-frequency vibration turning can be calculated as:
2
11
arcsin( ) 1 arcsin( )
22
FA
FF
i
AA
−
（12）
It can be seen from equation (13) that the separation conditions for low-frequency
vibration turning are related to the feed rate, amplitude, and the decimal part of the
frequency rotation ratio. Firstly, the tool feed rate needs to be less than twice the
amplitude, meaning that there are peaks in the tool paths of adjacent two turns.
Otherwise, regardless of the frequency rotation ratio, the machining will always be
continuous. Secondly, the decimal part of the frequency rotation ratio needs to
fluctuate within a certain range, ensuring that the tool trajectories of adjacent cycles
meet the misalignment requirements.
3 Experimental designs
The experiment platform is shown in Fig.5, using the CA6140 horizontal lathe as the
experimental machine. The maximum spindle speed of the machine is 1400r/min, and
the maximum workpiece rotation diameter is 400mm. The blade is made of hard alloy
coated blade from Hongju Technology Milling Cutter corporation, and the coating
material is TiAlN. The blade is installed on the tool rod of Warlock Company to
ensure the vibration effect of the tool. The LFVAT device is installed on the turret
through fixtures and dynamometer. The workpiece material is nickel-based alloy
Inconel718, with a diameter of 80mm, as shown in Fig.5.
LFVAT
Horizontal lathe
Workpiece
Dynamometer
Cutting tool
Fig.5 Cutting experiment platform
Fig.6 is schematic diagram of the cutting force measurement device. The cutting
force is mainly measured by Kistler9257B three-way piezoelectric dynamometer. The
sensitivity in the X and Y directions is -7.5pC/N, the sensitivity in the Z direction is
-3.7pC/N, the range in the X and Y directions is -5000~5000N, and the range in the Z
direction is -5000~10000N. The sampling frequency used in the experiment is 10 kHz.
The relative motion between the tool and the workpiece generates cutting force.
Based on the piezoelectric effect, the dynamometer obtains the three-way force and
converts it into the corresponding electrical signal, which is transmitted to the
computer through a charge amplifier and a digital collector for data processing.
Spindle
Workpiece
Three-jaw chuck
Cutting tool
Dynamometer
Charge
amplifier Digital collector
Computer
Fig.6 Schematic diagram of cutting force measurement device
The cutting temperature is mainly obtained through the FILR-T340 infrared
thermal imager. The temperature measurement interval of the equipment is -20℃ to +
1200℃, and the measurement accuracy is ± 2℃. In addition, the wear status of the
tools and the surface morphology of the workpiece are obtained through the Keyence
VHX-5000 microscope.
The cutting parameters are shown in Table 2, where the conventional turning
compares the low-frequency vibration turning. When conducting relevant experiments,
different cutting parameter combinations in the table will be used separately.
Table 2. Turning experiment parameters
Cutting speed v
（m/min）
Feed rate F
（mm/r）
Cutting depth ap
（mm）
Amplitude A
（mm）
Frequency rotation ratio
ωf
conventional
turning
25、31、40、50、
63、80
0.08 、0.10 、
0.15、0.20、0.25
0.20 、0.30 、
0.40、0.50
0
0
Vibration
turning
25、31、40、50、
63、80
0.08 、0.10 、
0.15、0.20、0.25
0.20、0.30
0.40、0.50
0.05 、0.10 、
0.15、0.2
4.5、5.5、6.5、7.5、10、10.2、
10.4、10.5、10.6、10.8、11
4 Experiment results and analysis
4.1 Chip morphology
The change rule of chip morphology with feed rate，amplitude, and the decimal part of
frequency rotation ratio under the same experimental conditions for conventional
turning and low-frequency vibration-assisted turning are shown in Figs.7-9.
Fig.7 shows the change of chip morphology with feed rate at v=50mm/min,
ap=0.4mm, A=0.1mm and ωf =5.5. It can be seen that the vibration turning has more
obvious chip breaking effect, which is sequentially manifested as small spiral
segments, C-shaped flakes with a small amount of fragmentation, C-shaped flakes,
and spring shaped. When the feed rate is greater than 0.2mm/r, there is no significant
difference between its chips and conventional turning, and the vibration chip breaking
effect is not obvious, mainly because low-frequency vibration cutting does not meet
the separation conditions.
Turning method
Conventional turning
Vibration turning
Feed rate
（mm/r）
0.08
0.1
0.15
0.2
Fig.7 Change of chip morphology with feed rate
Fig.8 shows the change of chip morphology with amplitude at v=50mm/min,
ap=0.4mm, F=0.1mm/r and ωf =5.5. It can be seen that when the amplitude and feed
rate are the same, the chip breaking effect is the best. And when the amplitude is
greater than 0.2mm, the chip breaking effect is not significant, this is mainly due to
not meeting the separation conditions.
Amplitude （mm）
0
0.05
0.1
0.15
0.2
Fig.8 Change of chip morphology with amplitude
Fig.9 shows the change of chip morphology with the decimal part of frequency
rotation ratio at v=50mm/min, ap=0.4mm, F=0.1mm/r and A =0.1. It can be seen that
when the frequency rotation ratio is an integer, there is basically no chip breakage.
And when the frequency to speed ratio is 10.5, the chip breaking effect is the best.
Therefore, the decimal part of frequency rotation ratio should be taken at 0.5 as much
as possible.
Frequency rotation ratio
10
10.2
10.4
10.5
10.6
10.8
Fig.9 Change of chip morphology with the decimal part of frequency rotation ratio
4.2 Cutting force
The change rule of main cutting force, feed force and cutting depth resistance force
with cutting speed, feed rate and cutting depth under the same experiment conditions
for conventional turning and low-frequency vibration-assisted turning is shown in
Fig.10.
0
50
100
150
200
250
300
350
25 30 35 40 45 50 55 60 65 70 75 80
Cutting force（N）
Cutting speed (mm/min)
Cutting depth resistance force_Vibration turning
Cutting depth resistance force_Conventional turning
Feed force_Vibration turning
Feed force_Conventional turning
Main cutting force_Vibration turning
Main cutting force_Conventional turning
0
50
100
150
200
250
300
350
400
Cutting force（N）
0.08 0.1 0.15 0.2 0.25
Feed rate (mm/r)
Cutting depth resistance force_Vibration turning
Cutting depth resistance force_Conventional turning
Feed force_Vibration turning
Feed force_Conventional turning
Main cutting force_Vibration turning
Main cutting force_Conventional turning
（a）Cutting speed （b）Feed rate
0
50
100
150
200
250
300
350
Cutting force（N）
0.2 0.3 0.4 0.5
Cutting depth (mm)
Cutting depth resistance force_Vibration turning
Cutting depth resistance force_Conventional turning
Feed force_Vibration turning
Feed force_Conventional turning
Main cutting force_Vibration turning
Main cutting force_Conventional turning
（c）Cutting depth
Fig.10 The change of cutting force with cutting speed, feed rate and cutting depth
Fig.10 (a) shows the change rule of cutting force with cutting speed at F=0.1mm/r,
ap=0.4mm, A=0.1mm and ωf =5.5. It can be seen that the cutting force decreases with
the increase of cutting speed under conventional turning or vibration turning. When
the cutting speed is low, the separation effect of low-frequency vibration- assisted
makes the cutting force much lower than the conventional turning. There is a force
reduction effect in the cutting speed range of 25-40m/min. When the cutting speed
reaches 63m/min, the force reduction effect of vibration turning is lost. This is mainly
because as the cutting speed increases, the separation time between the tool and the
workpiece is weakened, leading to an increase in the contact ratio between the tool
and the workpiece.
Fig.10 (b) shows the change rule of cutting force with feed rate at v=50mm/min,
ap=0.4mm, A=0.1mm and ωf=5.5. It can be seen that the cutting force increases with
the increase of feed rate under conventional turning or vibration turning. This is
mainly because as the feed rate increases, the instantaneous cutting thickness of the
tool increases, and the material removal rate increases, resulting in an increase in
cutting force. When the feed rate is less than 0.2mm/r, which means that the
separation condition is met, vibration turning has better effect on reducing force
compared to conventional turning. However, as the feed rate increases, the decrease
amplitude decreases. When the feed rate is greater than 0.2mm/r, which means that
the separation condition is not met, the increase in cutting path of vibration turning
will lead to an increase in cutting force compared to conventional turning.
Fig.10 (c) shows the change rule of cutting force with cutting depth at
v=50mm/min, F=0.1mm/r, A=0.10mm and ωf=5.5. It can be seen that the influence of
cutting depth on cutting force is the most significant. With the increase of cutting
depth, the cutting force of conventional turning and vibration turning increases. When
the cutting depth reaches 0.3mm, the cutting force sharply increases. This is mainly
because when the tool cuts into the workpiece until it reaches the specified depth, its
plastic deformation is large, the instantaneous cutting layer thickness increases sharply,
and the material removal rate intensifies, resulting in a sudden increase in the main
cutting force.
In summary, within the appropriate cutting speed range of 25-63 m/min and the
feed rate range that meets the separation conditions, low-frequency vibration-assisted
turning device has a force reduction advantage compared to conventional turning.
Conversely, its cutting force will increase and the force reduction effect will be lost.
4.3 Cutting temperature
The change rule of cutting temperature with cutting speed, cutting depth, and feed rate
for conventional turning and low-frequency vibration-assisted turning is shown in
Fig.11.
Fig.11 (a) shows the change rule of cutting temperature with cutting speed at
F=0.10mm/r, ap=0.4mm, A=0.10mm and ωf=5.5. It can be seen that the cutting
temperature shows an upward trend with the increase of cutting speed. When the
cutting temperature is greater than 63 m/min, the cutting temperature rises slowly. The
cutting temperature of vibration turning is always lower than that of conventional
turning. This is mainly due to the interference of adjacent cutting trajectories during
vibration cutting, which forcibly cuts off the chips, causing some heat to be carried
away with the chips, and the temperature to decrease compared to conventional
turning. However, when the cutting speed reaches the critical speed, its separation
characteristics weaken, and the temperature will still slowly rise.
Fig.11 (b) shows the change rule of cutting temperature with feed rate at
v=50mm/min, ap=0.4mm, A=0.10mm and ωf=5.5. It can be seen that the cutting
temperature increases with the increase of feed rate, and when f=0.2mm/r, the
temperature is close to the conventional turning temperature. This is mainly because
when the feed rate is greater than 0.2mm/r, vibration cutting does not meet the
separation conditions.
Fig.11 (c) shows the change rule of cutting temperature with cutting depth at
v=50mm/min, F=0.10mm/r, A=0.10mm and ωf=5.5. It can be seen that as the cutting
depth increases, the instantaneous thickness of the cutting increases, the plastic
deformation of the workpiece intensifies, and rake face and chip rub violently,
resulting in an increase in cutting temperature. Compared with conventional turning,
vibration turning has a lower cutting temperature.
90
100
110
120
130
140
Cutting temperature（℃）
20 30 40 50 60 70 80 90
Cutting speed (mm/min)
Conventional turning
Vibration turning
95
100
120
125
130
Cutting temperature（℃）
110
105
115
Feed rate (mm/r)
0.08 0.1 0.12 0.14 0.16 0.18 0.2
Conventional turning
Vibration turning
（a）Cutting speed （b）Feed rate
130
135
Cutting temperature（℃）
0.45 0.5
Conventional turning
Vibration turning
Cutting depth (mm)
105
110
115
120
125
0.2 0.25 0.3 0.35 0.4
105
110
115
120
125
0.2 0.25 0.3 0.35 0.4
（c）Cutting depth
Fig.11 The change of cutting temperature with cutting speed, feed rate and cutting depth
4.4 Tool wear
Tool wear is most sensitive to changes of cutting speed. Under the conditions of
f=0.1mm/r, ap=0.2mm, A=0.10mm and ωf=5.5, the change rule of tool wear process
with cutting speed is shown in Fig.12.
Conventional turning
Vibration turning
0.05
0.10
0.15
0.20
0.25
0.30
0.35
0 10 20 30 40 50 60 70 80
Flank wear amount VB/mm
Cutting time (min)
Flank wear amount VB/mm
05 10 15 20 25 30 35 40
0.05
0.10
0.15
0.20
0.25
0.30
0.35
Cutting time (min)
Conventional turning
Vibration turning
（a）v=25m/min （b）v=31m/min
0.05
0.10
0.15
0.20
0.25
0.30
0.35
0.40
05 10 15 20 25 30 35 40
Flank wear amount VB/mm
Cutting time (min)
Conventional turning
Vibration turning
0.05
0.10
0.15
0.20
0.25
0.30
0.35
0.40
01.5 34.5 6 7.5 9 10.5 12
Cutting time (min)
Conventional turning
Vibration turning
Flank wear amount VB/mm
（c）v=40m/min （d）v=50mm/min
Fig.12 The change of tool wear amount with cutting time
Take the flank wear amount VB=0.3 mm as the tool blunting failure standard. At
cutting speed of 25mm/min-40mm/min, vibration turning can delay tool wear time
compared to conventional turning. Especially, when the flank wear amount VB is
between 0.15 and 0.20, stable wear is achieved for a long time. When the cutting
speed reaches 50 m/min, the tool wear of both conventional turning and vibration
turning rapidly deteriorates, reaching the blunting standard in short period of time
(9-12 min).
The flank wear state at v=50 m/min as shown in Fig.13.
Turning method
Conventional turning
Vibration turning
Cutting
time
（min）
3
200μm
Flank surface
Feed direction
Rake face
200μm
Feed direction
Flank surface
Rake face
6
200μm
Flank surface
Feed direction
Rake face
200μm
Feed directionRake face
Flank surface
9
200μm
Flank surface
Feed direction
Rake face
200μm
Flank surface
Feed directionRake face
12
200μm
Flank surface
Feed direction
Rake face
200μm
Flank surface
Feed direction
Rake face
Fig.13 The flank wear state at cutting speed of 50m/min
It can be seen from Fig.13 that whether it is conventional turning or vibration
turning, the flank surface is uneven and has slight chipping state. Especially for
conventional turning, the overall nose of tool is broken. This is mainly because the
high cutting force and cutting temperature of the tool in the conventional turning,
which can easily exacerbate tool wear under high cutting speed conditions.
4.5 Workpiece surface morphology
The workpiece surface morphology in conventional turning and low-frequency
vibration turning is shown in Fig.14.
(a) Conventional turning (b) Vibration turning
Fig.14 The workpiece surface morphology
It can be seen from Fig.14 that conventional turning produces regular groove
stripes, while low-frequency vibration turning forms periodic surface textures,
including features such as pits, sharp points, and ridges. This is mainly due to the
overlapping effect between tool space trajectories during low-frequency vibration
turning.
5 Conclusion
In this paper, an adjustable dual eccentric mechanism is used to develop the
low-frequency vibration-assisted turning device. Through performance testing, the
LFVAT device has good working stability and can meet the high-quality and efficient
processing requirements of nickel-based alloy. The results are summarized as follow:
(1) The misalignment angle of the dual eccentric mechanism is the main factor
affecting the amplitude of LFVAT device. The corresponding misalignment angle can
be obtained by matching radial through-holes of the eccentric shaft and eccentric
sleeve, and the amplitude adjustment is convenient.
(2) The separation effect of low-frequency vibration-assisted turning is closely
related to the feed rate, amplitude, and the decimal part of the frequency rotation ratio.
The feed rate needs to be less than twice amplitude, and the decimal part of the
frequency rotation ratio needs to fluctuate within certain range to achieve better
separation effect.
(3) The chips in low-frequency vibration-assisted turning gradually appear as
C-shaped chips from small spiral shaped chips, which is more beneficial for chip
discharge and prevents chips from wrapping around the tool.
(4) Compared to conventional turning, LFVAT device has a significant effect,
which can reduce cutting force, cutting temperature, delay tool wear, improve surface
quality, and increase tool life.
(5) Under appropriate process parameters, LFVAT improves chip removal
efficiency and has good application prospects in nickel-based alloy and other difficult
to machine materials.
Funding information The authors wish to thank the financial support for this work from the
Natural Science Foundation Research Project of Shaanxi Province (2021JQ-488), Doctor’s
Research Foundation of Xi’an University of Technology (Grant Number 102-451120014).
Author Contributions All authors contributed to the study conception and design, to the search in
the literature and to the reading of the relevant retrieved papers. WeiChao Shi proposed the
method and conducted the numerical simulation. He also drafted the manuscript. JianMing Zheng
and LingJian Zhu discussed the prediction model and revised the manuscript. Ting Chen,
ZhangShuai Jing, Chao Peng, Rong Xue and Qi LI conducted the experiment and processed data.
Declarations
Ethics approval The authors declare that this manuscript was not submitted to more than one
journal for simultaneous consideration. The submitted work is original and has not been published
elsewhere in any form or language.
Consent to participate All the authors consent to participate in this research and contribute to the
research.
Consent for publication All the authors consent to publish the research. There are no potential
copyright/plagiarism issues involved in this research.
Conflict of interest The authors declare no competing interests.
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