Finite element simulations of conventional and ultrasonically assisted turning processes with plane and textured cutting inserts

Abstract This paper investigates the performance of conventional turning and ultrasonically assisted turning (UAT) processes with plane and textured cutting inserts. Simulations based on the finite-element method were carried out using a software package ABAQUS/Explicit (Dassault Systemes, France). The obtained results were validated experimentally by employing a specially developed UAT setup. The purpose of the paper is to analyze cutting-force variation by the use of textured cutting inserts. Optimized dimensions of the texture pattern were used to model textured cutting inserts. The cutting-force variation in UAT was assessed with finite-element method, confirming diminishing cutting forces at a tool–workpiece interface during a noncontact time. The use of the textured cutting inserts in the UAT process resulted in the lowest cutting forces when compared to a plane tool in UAT as well as both plane and textured tools in the conventional turning process.