Development of a low-frequency vibration-assisted turning device for nickel-based alloy

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.