Development of Ultraprecision Elliptical Vibration Cutting Machine

经过两年的研究，本研究的目标已经圆满实现。取得的主要研究成果如下：1.研制了抑制两个方向振动干涉的椭圆振动系统。然后，设计了一种控制系统来跟踪平均共振频率，并保持两次振动的幅值和相位。超精密椭圆振动切割机的研制安装了上述研制的椭圆振动系统，研制出了超精密椭圆振动切割机。椭圆振动的最佳条件研究了椭圆振动条件如剪切角、切削力、表面粗糙度等对加工过程的影响，明确了最佳的椭圆振动条件。椭圆振动切割的实际效果以前的研究表明，应用椭圆振动切割可以显著减小切屑厚度，从而减小切削力。在本研究中，阐明了上述基本效应产生的实际效果。“*”应在包括切屑方向和切屑流向的平面上施加椭圆振动，以便最有效地拔出切屑和减小切削力。*“椭圆振动切割几乎完全抑制了毛刺的产生。”*“当使用柔性工件或刀具时，加工精度得到提高，再生颤振得到显著抑制。”*“椭圆振动切割抑制了工件材料与刀具的粘附性。”

The objectives of this research have been successfully attained after two years of research. The major research results obtained are as follows ;1. Development of elliptical vibration systemA resonator for elliptical vibration is developed, in which interference between two directional vibrations is restrained. Then, a control system is developed to chase the average resonant frequency and to keep the amplitudes and the phase of the two vibrations.2. Development of ultraprecsion elliptical vibration cutting machineAn ultraprecsion elliptical vibration cutting machine is developed by installing the above developed elliptical vibration system.3. Optimum conditions of elliptical vibration Effects of elliptical vibration conditions on the cutting process, i.e. shear angle, cutting force, surface roughness, etc., are investigated, and the optimum elliptical vibration conditions are clarified.4. Practical effects of elliptical vibration cuttingIt was reported in the previous research that the chip thickness and hence the cutting force are reduced drastically by applying elliptical vibration cutting. In the present research, it is clarified that the above fundamental effects lead to the following practical effects."*" The elliptical vibration should be applied in the plane including the cutting direction and the chip flow direction, so that the chip can be pulled out and the cutting force is reduced most effectively."*" Generation of burr is restrained almost completely by applying the elliptical viration cutting."*" Machining accuracy is improved and regenerative chatter vibration is restrained-significantly, when a flexible workpiece or tool is used."*"Adhesion of workpiece material to the tool is restrained by the elliptical vibration cutting.