Dynamic Cutting Force Prediction Model and Experimental Investigation of Ultrasonic Vibration-Assisted Sawing

In conventional band sawing, the long-span compression of the flexible saw blade often results in large fluctuations in cutting force, low cutting efficiency, and poor force predictability. To address these issues, this study investigates the dynamic cutting force modeling and experimental validation of ultrasonic vibration-assisted band sawing using 304 stainless steel as the workpiece material. Based on an analysis of the band sawing mechanism, an ultrasonic vibration-assisted approach is proposed to modify the contact conditions between the saw blade and the workpiece. A dynamic model of the saw blade is established using the string vibration equation, and a multi-tooth dynamic cutting force prediction model is further developed by incorporating variable cutting depth characteristics under ultrasonic vibration. Comparative experiments are conducted between conventional sawing and ultrasonic vibration-assisted sawing to validate the proposed model. At feed rates of 0.1–0.4 mm/s and preload values of 0.1–0.5 mm, the proposed model predicts dynamic cutting forces with good agreement to experimental results, achieving an average relative error of 5.44%. Under typical cutting conditions for difficult-to-machine materials, ultrasonic vibration-assisted sawing reduces the average cutting force and feed force by approximately 15% and 18%, respectively, while decreasing surface roughness along the feed direction by about 21%, thereby improving sawing efficiency and surface quality.