This article reveals the chip formation and the reducing of cutting force mechanisms of nickel-based superalloy Inconel 718 under elliptical vibration cutting using finite element analysis software. The results are compared with traditional cutting methods. The elliptical motion trajectory of the tool in elliptical vibration cutting machining is analyzed, and a two-dimensional finite element elliptical vibration cutting model is established. The effects of dynamic impact on the elliptical vibration cutting of Inconel 718 were discussed in terms of the surface morphology, chip formation mechanism, and cutting force reduced mechanism. The simulation results show that (1) compared with traditional cutting, the surface morphology of the workpiece machined by elliptical vibration cutting is better, and the machined surface has obvious elliptic indentation; (2) in traditional cutting, sawtooth chips are formed through shear slip, while in elliptical vibration cutting, the faster relative cutting speed [Formula: see text], higher tool-tip temperature, and smaller material removal cross-sectional area cause a more prominent thermal softening effect in the chip formation process than that in traditional cutting, which leads to the plastic flow to be dominant in the material removal process, resulting in the strip chips; and (3) compared with traditional cutting, the normal cutting force and the tangential cutting force in elliptical vibration cutting are separately reduced about 51.4% and 60.8%.

中文翻译：

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镍基高温合金Inconel 718椭圆振动辅助切削切屑形成机制模拟

本文利用有限元分析软件揭示了镍基高温合金Inconel 718在椭圆振动切削下的切屑形成和切削力减小机制。将结果与传统切割方法进行比较。对椭圆振动切削加工中刀具的椭圆运动轨迹进行分析，建立二维有限元椭圆振动切削模型。从表面形貌、切屑形成机制和切削力减小机制等方面讨论了动态冲击对Inconel 718椭圆振动切削的影响。仿真结果表明：（1）与传统切削相比，椭圆振动切削加工的工件表面形貌较好，加工表面有明显的椭圆压痕； (2) 传统切削中，锯齿状切屑是通过剪切滑移形成的，而椭圆振动切削中，相对切削速度越快[公式：见正文]、刀尖温度越高、材料去除截面积越小，导致切屑越小。切屑形成过程中热软化效应较传统切削更为突出，导致材料去除过程中塑性流动占主导地位，产生条状切屑； (3)与传统切削相比，椭圆振动切削的法向切削力和切向切削力分别降低约51.4％和60.8％。