The purpose of this study is to design and develop a Two-Dimensional Ultrasonic Vibration Assisted Micro-milling (2D UVAMM) system. Two-dimensional ultrasonic vibrations produced by 2D UVAMM are used to vibrate the workpiece in the micro-milling process. The system is developed using the principle of two Langevin piezoelectric transducers which have the ability to produce ultrasonic vibrations with small vibration amplitude. Process of 2D UVAMM design optimization was done by modal simulation using Finite Element Analysis method. Both Langevin piezoelectric transducers are designed to have symmetrical and asymmetrical vibration modes with the same natural frequency, so that elliptical pattern vibrations can be generated on the workpiece. The 2D UVAMM system operates at a natural frequency of 24 kHz and has an estimated total displacement on the normal and tangential axes respectively 0.766 μm and 0.382 μm. Two power sources with frequency of 24 kHz, phase difference of 90 degrees, and peak-peak voltage of 212 volt were supplied by an ultrasonic generator to excite both of the Langevin piezoelectric transducers. To confirm the developed 2D UVAMM system, experiments were conducted to compare the surface roughness of Aluminum 6061-T6 through micro-milling with conventional method and with additional of the 2D UVAMM system.

Vibration assisted machining (VAM) is a method that is widely used in improving the performance of machined products. External vibrations with high frequency to ultrasonic range along with an meso-micrometer amplitude are given to the cutting tool or workpiece. This will result in a periodic separation phenomenon, hence reducing the cutting force which has positive impacts on increasing tool life and machined surface quality. Among the high-precision machining processes, micro-milling which has the ability to produce complex components with 2D and 3D features, can also be applied with the vibration assisted method, known as vibration assisted micro-milling (VAMM). Based on the direction of vibration given in the machining process, there are 1D VAMM with linear vibrations and 2D VAMM with circular or elliptical trajectory vibrations. However to date, neither developed 1D nor 2D VAMM systems are still limited to the research of planar surfaces cutting using linear movement axes, meanwhile vibration assisted in inclination cutting of micro-milling using the rotational movement axes is still very rare. Therefore the purpose of this paper is to present the preliminary model in designing a 2D VAMM system for a 5-axis micro-milling machine. The system is powered using piezoelectric actuators as the vibration-producing actuators.

CNC milling machine is a production machine which widely used to manufacture many kinds of products. In the process of milling machining, the time needed to produce a component must be as minimum as possible to minimize the costs and its impacts on the environment. One of energy consumptions used in CNC milling machines is to supply electric motors for each axis of motions. Cutting energy consumption can be minimized by optimizing the cutting parameters, such as the cutting toolpath. Modelling and comparing the total energy consumption of the cutting process from different cutting toolpaths and strategies are important in selecting the right toolpath that has the smallest energy consumption. To achieve this goal, this study models the energy consumption during the cutting process. The model is then used to evaluate and compare different cutting toolpaths from different cutting strategies. Three prismatic and one sculptured part were used to examine the model of cutting energy consumption. A Graphical User Interface is also developed to simplify the comparison and evaluation process. Through this process it will be possible to predict energy consumption in the cutting toolpath and hence enable the selection of the right toolpath to reduce energy consumption in machining.

Micro products or micro components are commonly used in today’s world. Research around micromanufacture technologies to produce a better product quality has been going on extensively. Ultrasonic vibration assisted micromilling (UVAM) is one of the technologies that can give a better machining qualities over the conventional ones. One of the benefits UVAM can give is reducing the machined surface roughness. The purpose of this paper is to give an idea how vibration assisted micromilling can give a better surface roughness quality. The theoritical surface roughness geometry model is made using MATLAB software. The cutting tool used in the simulation is end mill. There is a feature of the cutting tool called bottom cutting edge angle. This feature will be considered on this paper. The effects of the bottom cutting edge on workpiece machined surface can be looked visually from the simulation. Thus, the effects of cutting process using UVAM on the workpiece surface can be looked as well through the simulation.

The third paragraph on the 1 Introduction section should be replaced as follows:Milling is one of the process of removing material which occurs because of the contact between the cutting tool that rotates on the spindle with the workpiece gripped on the machine table. In the digital era, there are many automated machines that are increasingly facilitating the production process, including milling machines. Many large industries have switched to CNC (Computer Numerical Control), but not a few manufacturers are still utilizing manual milling machines for production activities. Although it still operating on the same basic principles, modern CNC milling machines are significantly different from older milling machines. CNC machining plays an important role in current mass manufacturing because of its ability to achieve high accuracy and precision as well as its ability to accept computer commands for motion control [5].