Effects of Controlled Modulation on Interface Tribology and Deformation in Machining

The effects of superimposed, low-frequency modulation on contact conditions at the tool–chip interface and mechanics of machining are analyzed. It is shown that modulation can disrupt the severity of the tool–chip contact, enabling enhanced lubrication of this contact; and discretize chip formation to small dimensions with controlled size and shape. The deformation strain in the chip is also reduced, suggesting a 40% reduction in energy of machining due to the modulation. Conditions of frequency and amplitude for achieving these effects are presented and confirmed using a compact modulation device that can be retro-fitted onto conventional machine platforms. Implications for enhancing efficiency of industrial machining processes are briefly discussed.

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