Parametric Study of the Cutting Process and Surface Formation during Elliptical Vibration Assisted Single Point Cutting

Elliptical vibration cutting has enabled the fabrication of numerous functional surfaces such as optical quality surface finishes, micro/nano surface texturing, and improved cutting force reduction on ferrous and other hard‑to‑cut materials. This wide range of capabilities comes from the high‑frequency elliptical vibrations produced at the tool tip, ultimately introducing discontinuous contact between the cutting tool and workpiece. However, despite the relative use of this technology, there has been limited investigation on the overarching parametric influence that its cutting parameters have on process outcomes such as cutting forces and surface roughness formation.The current thesis addresses this research gap with the development of a parametric study for elliptical vibration assisted single point cutting. More specifically, the study encompasses analytical, experimental and finite element method analyses of the cutting forces and surface roughness. Ultimately, the results indicate the functional dependence between elliptical vibration process parameters and the resulting cutting forces and surface roughness. Cumulatively, this contribution enables effective recommendations for future enhancements involving user‑required cutting force reduction and/or surface quality improvements.