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<p>To gain a deeper understanding of the removal mechanism in ultrasonic vibratory cutting, this study employed a numerical simulation method based on the Johnson-Cook fracture criterion to systematically investigate the variations in stress triaxiality, temperature, and strain rate of the cutting layer under different vibration frequencies. The results indicate that, compared to traditional cutting, the stress triaxiality in the cutting layer during ultrasonic vibration cutting exhibits a wider range of distribution, presenting a highly negative stress triaxiality state. This condition increases both the fracture stress and contact stress of the material, resulting in the peak cutting force following a “trend of increasing and then decreasing” with the frequency of vibration, while the average cutting force is lower. Furthermore, the high strain rate in ultrasonic vibration cutting has a similar effect to that of the vibration frequency on the cutting layer, resulting in the highest strain rate observed in the cutting layer. Additionally, the high strain rate effect of ultrasonic vibratory cutting can cause early damage to the cutting layer. Compared with conventional cutting, ultrasonic vibratory cutting can achieve a larger shear angle and shear strain, while simultaneously enabling efficient material removal with a smaller cutting force.</p>

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Research on the mechanism of material removal in ultrasonic vibration cutting based on Johnson-Cook failure criterion

  • 期刊论文

  • 发表日期：

    2025年8月2日

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  • Jiayuan Luo,
  • Zhicheng Tang,
  • Jian Wang,
  • Cong Gao

摘要

To gain a deeper understanding of the removal mechanism in ultrasonic vibratory cutting, this study employed a numerical simulation method based on the Johnson-Cook fracture criterion to systematically investigate the variations in stress triaxiality, temperature, and strain rate of the cutting layer under different vibration frequencies. The results indicate that, compared to traditional cutting, the stress triaxiality in the cutting layer during ultrasonic vibration cutting exhibits a wider range of distribution, presenting a highly negative stress triaxiality state. This condition increases both the fracture stress and contact stress of the material, resulting in the peak cutting force following a “trend of increasing and then decreasing” with the frequency of vibration, while the average cutting force is lower. Furthermore, the high strain rate in ultrasonic vibration cutting has a similar effect to that of the vibration frequency on the cutting layer, resulting in the highest strain rate observed in the cutting layer. Additionally, the high strain rate effect of ultrasonic vibratory cutting can cause early damage to the cutting layer. Compared with conventional cutting, ultrasonic vibratory cutting can achieve a larger shear angle and shear strain, while simultaneously enabling efficient material removal with a smaller cutting force.