Low cutting forces can signi cantly reduce the risk of damage to sensitive tissues adjacent to the bone. Because of its better control of the incision, lower cutting force and reduced postoperative complications, the application of Ultrasonic tools in bone-cutting is of concern to surgeons. In this study, through the application of a full factorial design of experiments, the e ects of changes in cutting tool geometry, Ultrasonic power, bone-cutting direction, and tool speed on the cutting forces of cortical bone are assessed simultaneously. The variance and regression of the experimental data are analyzed, and the impact of factors and interactions of the elements on the cutting forces are discussed. The adjusted coe cient of determination (R 2 adj) of the main cutting force and cutting resistance force of the statistical model were 91. 49% and 91. 15%, respectively. Both the blade geometry and Ultrasonic power, together with their interactions, are the most in uential factors in the cutting forces, contributing 82. 2% and 86. 6%, respectively. The formation of teeth in the cutting edge improves the cutting process and reduces the cutting force by about 40%. To obtain high e ciency and low cutting force, it is recommended to use an Ultrasonic-powered toothed edge blade with a pitch of 1 mm, a low vertical velocity, and a high longitudinal speed.

Characteristics such as excellent mechanical properties, high heat resistance, corrosion resistance and low density have made composites like carbon fiber widely used in various industries including medical, aerospace and automotive. However, due to characteristics such as poor thermal conductivity, low cutting surface quality and high strength, it is difficult to cut it using conventional methods. The aim of this article is to design and build a type of cutting tool that uses Ultrasonic waves to reduce the cutting force and improve the cutting surface quality of carbon fiber workpieces. In this research, the design and construction of the horn part of the cutting tool is specifically discussed. First, a stepped horn is designed by performing analytical calculations, and then by adding a conical part with different angles to it, the effect of changing the angle on the amplitude amplification, modal spacing and stress distribution has been investigated by finite element simulation method.The results of numerical simulation show the insignificant effect of changing the angle of the conical part on the result. Finally, the optimized design is built.The results of experimental tests show that the use of Ultrasonic waves has a significant effect in reducing the cutting force up to one-sixteenth and significantly improving the quality and straightness of the cutting edge of the carbon fiber workpiece compared to the case without Ultrasonic assistance.

The purpose of this paper is to investigate the cutting forces in Ultrasonic assisted milling (UAM) process of AISI 1020 steel. Vibrations are imposed to the workpiece by a special fixture we developed. With different values of depth of cut, the cutting forces in both conventional milling (CM) and UAM are measured. The obtained cutting forces in UAM are less than the ones in CM. The effect of Ultrasonic vibration on the cutting forces decreases in large values of cutting depth in comparison with its corresponding low values. Experimental data show that UAM decreases the cutting forces in comparison with CM by 8% in average.

One directional and elliptical vibration cutting of IN738 at Ultrasonic frequency has been investigated both experimentally and by FEM in the present study. The influence of each process on the cutting force was studied. The FEM modeling was carried out by using MSC-MARC. The results were compared with the experimental findings of the conventional cutting. The Ultrasonic vibration was applied to a rigid cutting tool along the cutting velocity in one directional vibration cutting. In elliptical vibration cutting the vibration was applied both along the cutting velocity and in the chip flow direction. The experiments were carried out on an ultra-precision CNC lathe with single crystal diamond tools. The same effects were confirmed in the machining practice and by FEM. It was quite feasible when machining IN738 to obtain the advantages of elliptical vibration cutting already reported for some other materials such as copper, aluminum, tungsten and super alloys.

Vibration cutting (VC), elliptical vibration cutting (EVC) and ordinary cutting (OC) of In 738 work-pieces have been experimentally investigated in the present research. The experiments were carried out by using single crystal diamond tool and ultra-precision CNC lathe. Vibration frequency is 36.16 KHz and the amplitude is 4 mm. The influence of various cutting parameters including cutting speed, feedrate, vibration amplitude and phase angle on the cutting force, surface roughness and tool life have been studied and the results have been compared. The results indicate that the cutting force in EVC is much less than the two other processes. The surface roughness in both the cutting and feed directions was also less than those in other processes.

Calculation the cutting force in machining processes is of great importance. In this paper, undeformed chip thickness in one-dimensional Ultrasonic vibration assisted milling is calculated and then, a model for determining the cutting force in this process is presented. Analytical relations show that in Ultrasonic assisted milling (UAM), the maximum cutting force is greater than in conventional milling (CM), but the average cutting force is decreased. To verify the proposed relations, with the aid of a particular experimental setup, one-dimensional vibration in feed direction is applied to workpiece and cutting force in CM and UAM is measured experimentally. Greater maximum cutting force in UAM and decrease of average cutting force in UAM compared to CM is observed experimentally as well. Comparison of average values of cutting force shows that the analytical relations for predicting the cutting force have 16% average error in CM and 40% average error in UAM. Given that the analytical calculation of undeformed chip thickness and cutting force in UAM and also comparison of experimental forces with the modeled ones has been done in this paper for the first time, the accuracy of proposed relations are acceptable.

Material cutting is one of the most widely used industrial processes, which is always accompanied by challenges. One of these challenges is the ability to cut materials with high elasticity such as rubber or soft and crispy materials such as cake. In order to increase the life of the tool and achieve a suitable and accurate cutting surface and achieve a high cutting speed, the technology of high power Ultrasonic vibrations is used in the modern industries of tire and rubber production and food industries. The proper design of the Ultrasonic cutting tool, guarantees the proper performance and the tool life. The design and manufacture of Ultrasonic cutting horns is complicated due to the influence of various factors on the shape and dimensions of the part. In this article, the effect of the dimensional parameters of the horn design on two important output factors, namely the resonance frequency of longitudinal vibration mode and the uniformity of the vibrations of the front surface of the Ultrasonic cutting horn made of titanium alloy, have been investigated and analyzed. The results have shown that by using design improvements in finite element software, it is possible to achieve a cutting horn with a frequency close to the nominal design frequency and with the highest uniformity of the vibration amplitude on the front surface of the horn.

Ultrasonic vibration assisted drilling is a new technique, and one of the modern and promising processes for drilling metals, especially metal alloys with low machinability. In this paper, a set of laboratory tests is used to investigate the effect of using Ultrasonic vibrations on the force required for drilling of the thin aluminum specimens. For this purpose, three aluminum workpieces with different thickness are drilled under three different rotation speeds, and four different penetration rates. The results showed that in two aluminum workpieces, 1 and 1. 5 mm, the use of Ultrasonic vibrations generally reduced the axial force, but in the 2 mm workpiece, it is impossible to understand a meaningful effect of applying Ultrasonic vibrations. In other words, it can be said that adding Ultrasonic vibrations with constant amplitude and frequency does not have the same effect on drilling in different conditions, and to reach the most efficient drilling,the characteristics of optimal vibration should be studied.