Friction creates heat, promotes wear, and wastes power, so the reduction of

friction

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Chapter 3: The analysis of forces and torques in vibration assisted
tapping.
The main objective of analytical model presented in this study is describing the
relationship between friction torque and vibration frequency and amplitude. The assumptions
made for this analysis are,

1. Neglect the effect of ultrasonic vibration on toughness or strength reduction of

workpiece material.
2. Neglect the effect of ultrasonic vibration on tool-chip interference.

3.1 Cutting forces in vibration assisted tapping

It is very difficult to predict accurately instant force for a vibration assisted tapping
operation. Because of very complex tap geometry, the forces vary with tap and work piece
position. Cutting force act on the cutting tooth divides into three components. They are- 1) axial
force-Fac , 2) radial force-Frc and, 3) tangential force-Ftc [A, B].
In figure 3-1, Ps represents the tool cutting edge plane. The workpiece and i cutting tooth
coordinate system is represented by symbol XL, YL, ZL and XW, YW, ZW respectively.

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 Figure 3- 1 Tap structure and force analysis [A]

Figure 3- 2 forces on elementary tooth [B]

3.1.1 Axial force-Fac

Tapping process axial force is a reversed normal pressure produced between the side of
direction of feed and a tapped thread groove, represented by N2i. Influence of a normal ultrasonic
vibration on reduction of average normal pressure. Zhang [3] proposed the theoretical model to
represent effect of normal vibration on normal pressure based upon exterminate result.
Pi=W −CA cos (wt )…………………………………. (3.1)

Here, C is a constant related to the friction couple material, W is the static normal, A is
amplitude of vibration and w is angular velocity. The equation indicates that W < CA cos (wt),
value of N 2 i is negative. This means that two bodies separate periodically. Therefore,

N 2 i=
{
W −CA cos ( wt ) t 1 ≤ t ≤t 2
0 0 ≤ t ≤ t 1∧t 2 ≤t ≤ T
…………….…. (3.2)

Distribution of load along with the time is shown in Figure 4-2, with t 1 and t2 are the
starting and finishing times of contact for a given period of time T.

Figure 3- 3 normal pressure distribution [B]

Total axial load in ultrasonic vibration assisted tapping operation is

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 n
F ac ¿ ∑ F aci…………………………………………..…….. (3.3)
i=1

Here, n is a total number of teeth.

3.1.2 Radial force-Frc

Under the ideal situation, the radial forces components caused by every tap tooth all pass through
a tap axis. Hence, resultant radial force zeros.
F rc = ∑ F rci = 0…………………………………………..…….. (3.4)

3.1.2 Tangential force-Ftc

Tapping process tangential force is a force act on cutting tooth in opposite direction of resultant
cutting speed. No effect of ultrasonic vibration on total tangential force.

m
F tc ¿ ∑ F tci…………………………………………..…….. (3.5)
i=1

Here, m is a total number of cutting teeth.

3.2 Torque in vibration assisted tapping

Total torque in vibration assisted tapping divides into two components. They are- 1)
cutting torque and, 2) friction torque. Friction forces have major role in developing the torque, so
reducing tapping torque can be realized by reducing fraction force.
T =T C + T F

3.2.1 Cutting torque-Tc

Cutting torque in tapping depends on tangential component of force made by every tap
tooth. No effect of ultrasonic vibration on total cutting torque (Neglect the effect of ultrasonic
vibration on toughness or strength reduction of workpiece material).

m
T c ¿ ∑ F tci∗r i…………………………………………..…….. (3.6)
i=1

Here, r i is a radius of i cutting edge.

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3.2.1 Friction torque-Tf
The frictional contacts between workpiece and cutting tooth are divided into four regions.
They are-
1. Contact between rake face and chip- F gi.
2. Contact between Top face major cutting edge and newly machined surface- f i.
3. Contact between Top side flank of minor or side cutting edge and newly machined
surface- f 1i .
4. Contact between bottom side flank of minor or side cutting edge and newly
machined surface- f 2i .

m
T f ¿ ∑ F gi∗r i +¿ ¿ ) * cosβ ] * r i …………………………………………..…….. (3.7)
i=1

3.2.2 Effect of ultrasonic vibration on contact between Top face major

cutting edge and newly machined surface.
In this case direction of vibration is right angle to the direction of sliding. Kumar et al. [c]
explain reduction of the sliding friction of metals by application transverse ultrasonic vibration.
Block diagram representation of actual contact and vibration direction is shown in Figure 3-4.
Top block represent the tooth and bottom workpiece.

Figure 3- 4 block diagram representation of contact between Top face major cutting edge and
newly machined surface [c]

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 Kumar et al. [c], proposed the theoretical model to represent effect of normal vibration on
frictional force.

( )
T
1 v
f i= ∫
T 0
f 0 cos tan −1 v sin wt dt …………………………….... (3.8)
vs

3.2.2 Effect of ultrasonic vibration on contact between Top and bottom

side flank of minor or side cutting edge and newly machined surface.
In this case direction of vibration is normal to the direction of sliding. Zhang [d] explain
reduction of the sliding friction of metals by application normal ultrasonic vibration. Block
diagram representation of actual contact and vibration direction is shown in Figure 3-4. Top block
represent the tooth and bottom workpiece.

Figure 3- 5 block diagram representation of contact between Top and bottom side flank of minor
or side cutting edge and newly machined surface [c]
Zhang [d] proposed the theoretical model to represent effect of normal vibration on
frictional force
T
1
f 1i , 2 i= ∫ ∅ N dt ………………………….…………………………. (3.9)
T 0 t 1 i ,2 i

Here, Normal pressure act on flank face is function time and the coefficient of friction is a
function of micro displacement in micro slip region.

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 Figure 3-6 the relationship between coefficient of friction and relative displacement [e]
Adachi et al [9], based upon exterminate result give relationship between dynamic normal
load and static normal load.

N 1 i ,2 i=W −CA cos( wt )…………………………………. (3.10)

Here, C is a constant related to the friction couple material, A is amplitude of vibration

and w is angular velocity. The equation indicates that W < CA cos (wt), value of W d is negative.
This means that two bodies separate periodically. Therefore,

N 1 i ,2 i=
{
W −CA cos ( wt ) t 1 ≤ t ≤ t 2
0 0 ≤ t ≤ t 1∧t 2 ≤t ≤ T
… (3.11)

From figure 3-6, we get-

{
μk u t ≤ u 1
∅ t = C 1 u t −u1 ≤ ut ≤ u1 ……………………………………………..…. (3.12)
−μk ut ≤−u1

Where, C 1 is a constant value for one friction couple. The relative displacement is,

{
t

ut = ∫ v dt t1 ≤t ≤t 2 ……….…. (3.13)
t1
0 0 ≤t ≤t 1∧t 2 ≤ t ≤ T

Based on equation (3.12) and (3.14)

{
C 1 ut t 1 ≤ t ≤ t 3
∅t = μk t 3 ≤t ≤t 2 ………………..…….. (3.14)
0 0≤ t ≤ t 1∧t 2 ≤ t ≤T

Here, t3 is time when the relative displacement attain the value u1

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