Determination of Material-Dependent Parameters and Friction in Ultrasonic-Vibration-Assisted Turning by Inverse Modeling

In this work, an inverse method is proposed to estimate the material-dependent parameters and friction based on the cutting force measurement. The basis of inverse method is the measurement of tool–chip contact length and cutting forces during conventional turning process. The cutting forces are calculated using analytical expressions. To demonstrate the inverse procedure, the workpiece material made of AI 6061 and carbide tool (VBMW160404) are considered. The inverse model predictions are compared with the classical optimization sequential quadratic programming (SQP) method with constraint and unconstrained problems, and experimental results are available in the literature. The material-dependent parameters are estimated using three different approaches, viz. inverse method, SQP method considering constrained and unconstrained optimization problems. It is found that the material-dependent parameters predicted by these methods are altered within 2% error. In a nutshell, the cutting forces and coefficient of friction estimated by the proposed inverse method are in good agreement with the experimental data. The proposed procedure can be applied to determine material-dependent parameters and friction in real time in manufacturing industry.