The objective of this study was to determine the effect of vibration behavior on workpiece surface properties in low-frequency vibration cutting. The effects of the parameters that determine vibration behavior on surface roughness were quantitatively evaluated through a comparison with other cutting conditions. Furthermore, by clarifying how the surface properties of the workpiece, such as roughness, roundness, and cross-sectional curves, change depending on the vibration behavior, a search for optimal conditions for low-frequency vibration cutting was conducted. The best surface properties were obtained under the condition of spindle rotation per vibration E=4.5. By using a value close to the minimum possible spindle rotation R=0.5 when the workpiece is retracted, it is expected to be effective in suppressing the variation in surface roughness at each phase angle; this variation is characteristic of low-frequency vibration cutting. Workpieces machined under low-frequency vibration conditions such as (E=2.5, R=1.0) and (E=3.5, R=1.0) were found to form characteristic surface patterns on the workpiece surface owing to a phenomenon in which the depth of the cut to the workpiece changes.

1. [1] A. Kitakaze, K. Noguchi, M. Muramatsu, S. Kato, K. Sannomiya, and T. Nakaya, “Development of Low Frequency Vibration-Cutting,” J. of the Horological Institute of Japan, Vol.60, No.215, pp. 2-6, 2016 (in Japanese). https://doi.org/10.20805/micromechatronics.60.215_2
2. [2] “Cutting Tools-World Markets, End-Users & Competitors: 2005–2010,” Dedalus Consulting, 2005.
3. [3] A. Miyake, A. Kitakaze, S. Katoh, K. Noguchi, K. Sannomiya, T. Nakaya, and H. Sasahara, “Chip control in turning with synchronization of spindle rotation and feed motion vibration,” Precision Engineering, Vol.53, pp. 38-45, 2018. https://doi.org/10.1016/j.precisioneng.2018.02.012
4. [4] S. Ramalingam and J. D. Watson, “Tool Life Distributions–Part1: Sjngle-lnjury Tool-Life Model,” Trans. ASME, J. Eng. Ind., Vol.99. No.3, pp. 519-522, 1977. https://doi.org/10.1115/1.3439271
5. [5] A. Miyake, H. Sasahara, A. Kitakaze, S. Katoh, M. Muramatsu, K. Noguchi, K. Sannomiya, and T. Nakaya, “Effect of Low Frequency Vibration Applied to Feed Direction on Turning Process,” Int. Symp. on Flexible Automation (ISFA), pp. 356-358, 2016. https://doi.org/10.1109/ISFA.2016.7790188
6. [6] R. Wertheim, J. Rotberg, and A. Ber, “Influence of High-pressure Flushing through the Rake Face of the Cutting Tool,” Annals of the CIRP, Vol.41, Issue 1, pp. 101-106, 1992. https://doi.org/10.1016/S0007-8506(07)61162-7
7. [7] I. S. Jawahir and C. A. van Luttervelt, “Recent Developments in Chip Research and Applications,” CIRP Annals – Manufacturing Technology, Vol.42, No.2, pp. 659-693, 1993. https://doi.org/10.1016/S0007-8506(07)62531-1
8. [8] E. Shamoto and T. Moriwaki, “Ultrasonic Elliptical Vibration Cutting,” CIRP Annals, Vol.44, No.1, pp. 31-34, 1995. https://doi.org/10.1016/S0007-8506(07)62269-0
9. [9] A. Miyake, A. Kitakaze, S. Katoh, M. Muramatsu, K. Noguchi, K. Sannomiya, T. Nakaya, and H. Sasahara, “Cutting Characteristics of Low Frequency Vibration-cutting,” Proc. of JSPE, pp. 591-592, 2016 (in Japanese). https://doi.org/10.11522/pscjspe.2016A.0_591
10. [10] Citizen Machinery Co., Ltd., “LEV technology.”https://cmj.citizen.co.jp/english/product/lfv/index.html [Accessed May 4, 2023]
11. [11] A. Miyake, A. Kitakaze, S. Sakurai, M. Muramatsu, K. Noguchi, K. Sannomiya, T. Nakaya, Y. Kamada, and H. Sasahara, “Influence on surface characteristics generated in Low Frequency Vibration Cutting,” Trans. of the JSME, Vol.86, No.892, 2020 (in Japanese). https://doi.org/10.1299/transjsme.20-00323
12. [12] J. B. Mann, Y. Guo, C. Saldana, W. D. Compton, and S. Chandrasekar, “Enhancing material removal processes using modulation-assisted machining,” Tribology Int., Vol.44, No.10, pp. 1225-1235, 2011. https://doi.org/10.1016/j.triboint.2011.05.023
13. [13] Y. Kakino, A. Matsubara, Y. Kohno, K. hloguchi, D. Murakami, and Y. Takata, “High Speed, High Productive Machining of Automobile Parts by Machining Center with High Speed and High Acceleration Rate,” Proc. Third Int. Conf. Progess of Cutting and Grinding, Vol.192, 1996.
14. [14] Z. J. Pei, D. Prabhakar, P. M. Ferreira, and M. Haselkorn, “A mechanistic approach to the prediction of material removal rates in rotary ultrasonic machining,” ASME. J. Eng. Ind., Vol.117, Issue 2, pp. 142-151, 1995. https://doi.org/10.1115/1.2803288
15. [15] R. Nakasawa, K. Sakai, and H. Shizuka, “The influence of additive elements on machinability of Lead free brass,” Proc. of JSPE, pp. 595-596, 2016 (in Japanese). https://doi.org/10.11522/pscjspe.2016A.0_595
16. [16] V. Bushlya, D. Johansson, F. Lenrick, J.-E. Ståhl, and F. Schultheiss, “Wear mechanisms of uncoated and coated cemented carbide tools in machining lead-free silicon brass,” Wear, Vols.376-377, Part A, pp. 143-151, 2017. https://doi.org/10.1016/j.wear.2017.01.039
17. [17] G. Preisinger and H. Neumater, “Brass Materials and their Application for Cages in Rolling Bearings,” Tribologie und Schmierungstechnik, Vol.60, No.6, pp. 54-58, 2013.
18. [18] H. Kimura, T. Kitahara, and K. Mitsui, “Estimation of Cutting Force in Micro-turining,” Proc. of JSPE, pp. 251-252, 2011 (in Japanese). https://doi.org/10.11522/pscjspe.2011A.0.251.0
19. [19] Y. Kondo, R. Hayashi, I. Yoshida, A. Kitakaza, K. Noguchi, K. Sannomiya, and T. Nakaya, “Development of Measurement and Evaluation Method for Surface Textures Manufactured by Low Frequency Vibration Cutting,” Trans. of the Society of Automotive Engineers of Japan, Inc., Vol.52, No.2, pp. 407-412, 2021 (in Japanese). https://doi.org/10.11351/jsaeronbun.52.407
20. [20] D. Brentnall and W. Rostoker, “Some Observations on Microyielding,” Acta. Met. Vol.13, Issue 3, pp. 187-198, 1965 (in Japanese). https://doi.org/10.1016/0001-6160(65)90195-1
21. [21] The Japan Institute of Metals and Materials, “Revised 4th Edition Metal Data Book,” Maruzen Publishing, 2004 (in Japanese).