Mechanism model of ultrasonic disc knife wear prediction

Ultrasonic cutting technology is widely applied in the machining of honeycomb composites due to its high efficiency and low-damage characteristics. However, its high-frequency vibration features lead to complex tool wear mechanisms, and existing models exhibit insufficient prediction accuracy. This paper proposes a wear prediction method for ultrasonic disc cutters that integrates kinematic mechanisms with dynamic experimental data. Through coupled kinematic and mechanical analysis, three-directional force expressions at the tool tip were established. An experimental platform was constructed to systematically acquire full life-cycle wear data of tools via orthogonal experiments. Combined with experimental data, an empirical formula for cutting forces was developed, and the expression for flank face normal force was derived. Subsequently, a flank face wear model was established based on the extended Archard wear theory. Experimental results demonstrate that the model achieves a full-cycle prediction accuracy of 87.92%, with accuracies reaching 92.70% and 94.70% during the initial and middle stages, respectively. This research provides a theoretical basis for optimizing ultrasonic machining parameters and holds significant engineering value for reducing production costs.