Numerical analysis in ultrasonic elliptical vibration cutting (UEVC) combined with electrical discharge assistance (EDA) for Ti6Al4V

This paper reports the numerical analysis results of ultrasonic elliptical vibration cutting (UEVC) combined with the electrical discharge assistance (EDA), called UEVC + EDA. UEVC delivers decreasing cutting forces, repressing side-burrs, and lowering tool wear. EDA is a cutting technique using a pulsed spark to remove material using thermal energy. Difficult-to-cut materials, such as Ti-6Al-4 V, can be cut effectively by combining these two techniques. A numerical study was performed using ABAQUS finite element analysis (FEA) software by investigating the von Mises stress, cutting forces, and temperature. Numerical analysis was carried out by modifying the ultrasonic vibration frequency, distance of the discharge pulse, discharge voltage, and discharge pulse radius. UEVC + EDA was compared numerically and experimentally with regular cutting (NC) and UEVC in terms of cutting force and tool temperature. The results showed that the UEVC + EDA method could improve the cutting condition by reducing the cutting force and von Mises stress and increasing the tool temperature.