Abstract: The separated ultrasonic elliptical vibration cutting is successfully applied to precision cutting due to its superior performances, such as low cutting force, the ability to suppress chatter, high quality surface finish and long tool life. For the purpose of giving play to the superiority of ultrasonic elliptical vibration cutting and extending its application fields, separated and unseparated ultrasonic elliptical vibration cutting experiments are carried out based on analyzing the elliptical vibration cutting process and the micro-surface formation mechanism. The results show that unseparated ultrasonic elliptical vibration cutting can still make the cutting forces decrease remarkably, reduce the work piece surface roughness, and improve the ability to suppress chatter. Meanwhile, the unseparated ultrasonic elliptical vibration cutting increases the machining efficiency further, which is about 2~3 times as high as the separated ultrasonic elliptical vibration cutting. But these advantages are weakened gradually with the increase of speed coefficient. All the cutting advantages will not be efficient when the speed coefficient is greater than 3.

Key words: Elliptical vibration, Machining, Unseparated, Vibration cutting, dissimilar aluminum alloy, lap joint, mechanical property, microstructure, pulse MIG welding