Abstract

Background: Problems, such as severe hardening and poor processing quality, are present in the cutting process of difficult-to-machine materials.

Objective: The aim of this study was to investigate and optimize the machining parameters of 630 stainless steel by using an independently designed 28-KHz double-excitation elliptical vibration cutting process.

Methods: Using the AdvantEdge platform and response surface method, the effects of the cutting speed v, feed rate f, and cutting depth a_p on the cutting forces Fx and Fy in the feed and depth directions, respectively, and cutting temperature T were analyzed. Then, regression prediction models with three response variables for each of the three independent variables were established, and the best cutting parameter combination was optimized. Finally, the results were obtained and validated through physical experiment methods.

Results: Results show that the error of the experimental results relative to the predicted ones under the optimized cutting parameter combination is less than 9%.

Conclusion: Based on the response surface method, the optimal cutting parameters are obtained, and the cutting force and cutting temperature are at a lower level. The findings indicate the feasibility of the optimized machining parameters and provide a reference for the selection of cutting parameters and the publishing of patents, and when ultrasonic vibration is used, for cutting difficult-to-machine materials.

Keywords: Finite element, multi-objective optimization, prediction model, response surface method, stainless steel, vibration cutting.