Cusp error reduction under high speed micro/meso- scale milling with ultrasonic vibration assistance

Ko, Jeong Hoon; Shaw, Kah Chuan; Chua, Han Kwang; Lin, Rong

doi:10.1007/s12541-011-0002-2

Cited by 25 publications

(10 citation statements)

References 17 publications

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“…Shen et al [45] also showed that ultrasonic vibration in the feed direction has a positive effect on the surface roughness when the vibrating frequency is far higher than the gyro-frequency of the spindle. Ko and his co-workers [79] found that the height of the remnant material, called "cusp," can be reduced by applying ultrasonic vibration during high-speed milling with narrow tool paths and removal depths of less than 1 mm, improving the quality of the milled surface considerably. For plastic metal machining with VAMilling, vibration assistance in the feed and cross-feed directions was carried out separately to understand the mechanism of directional effects for producing better machined surface quality.…”

Section: End Millingmentioning

confidence: 99%

State-of-the-art review on vibration-assisted milling: principle, system design, and application

Chen

Huo

Shi

et al. 2018

Int J Adv Manuf Technol

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Vibration-assisted machining (VAM) is an external energy assisted machining method to improve the material removal process by superimposing high frequency and small amplitude vibration onto tool or workpiece motion. VAM has been applied to several machining processes, including turning, drilling, grinding, and more recently milling, for the processing of hard-to-machine materials. This paper gives a critical review of vibration-assisted milling (VAMilling) research. The basic kinematic equations of 1D and 2D VAMilling are formulated and three typical tool-workpiece separation types are proposed. State-of-the-art on the principle and structural design of VAM systems are reviewed. The benefits and applications of VAMilling are discussed with emphasis on machining of hard-to-machine materials. Finally, the paper concludes with future possibilities for VAMilling.

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Section: End Millingmentioning

confidence: 99%

State-of-the-art review on vibration-assisted milling: principle, system design, and application

Chen

Huo

Shi

et al. 2018

Int J Adv Manuf Technol

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“…Vibration-assisted milling H13 [22], Al 6061 [51][52], AL6061-T6 [49] Achieved surface roughness (Ra) for AL6061 is 0.105 µm [52] Nearly 22% reduction in tool life [49] Vibration-assisted grooving Glass [25,32], Al2024 [26], Plexiglas [26],…”

Section: Work Materials Primary Characteristicmentioning

confidence: 99%

Hybrid micro-machining processes: A review

Chavoshi

Luo

2015

Precision Engineering

144

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Micro-machining has attracted great attention as micro-components/products such as microdisplays, micro-sensors, micro-batteries, etc. are becoming established in all major areas of our daily life and can already been found across the broad spectrum of application areas especially in sectors such as automotive, aerospace, photonics, renewable energy and medical instruments. These micro-components/products are usually made of multi-materials (may include hard-to-machine materials) and possess complex shaped micro-structures but demand sub-micron machining accuracy. A number of micro-machining processes is therefore, needed to deliver such components/products. The paper reviews recent development of hybrid micro-machining processes which involve integration of various micro-machining processes with the purpose of improving machinability, geometrical accuracy, tool life, surface integrity, machining rate and reducing the process forces. Hybrid micro-machining processes are classified in two major categories namely, assisted and combined hybrid micromachining techniques. The machining capability, advantages and disadvantages of the stateof-the-art hybrid micro-machining processes are characterized and assessed. Some case studies on integration of hybrid micro-machining with other micro-machining and assisted 2 techniques are also introduced. Possible future efforts and developments in the field of hybrid micro-machining processes are also discussed.

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“…Zarchi et al pointed out that the average milling force of UVAC was significantly lower than that of conventional milling by analyzing the cutting force model of one-dimensional UVAC of stainless steel AISI-420. In addition, the surface roughness was also changed under the conditions of low feed rate and high cutting speed [10][11][12][13]. Ding established a sine-sine and sine-cosine vibration model of micromilling cutting force to simulate the influence of feed rate on the cutting force and surface roughness.…”

Section: Introductionmentioning

confidence: 99%

Experimental Study of a Novel Ultrasonic Vibration‐Assisted Structure for Radial Milling

Ren

Zou

et al. 2021

Shock and Vibration

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A novel ultrasonic vibration-assisted structure for radial milling is proposed, and the ultrasonic vibration-assisted radial milling (UVARM) is further studied in terms of theoretical model and milling experiment. The motion and feed characteristics of UVARM are also analyzed. A special fixture is designed to construct the experimental platform of UVARM, in which the vibration is applied to the workpiece along the radial direction. The preliminary results show that with the increase of spindle speed, the milling force in both conventional cutting (CC) and UVARM experiments tends to increase. In addition, when the feed per tooth increased, the milling force increased. With the involvement of ultrasonic vibration, the milling force is significantly reduced, with the maximum reduction reaching 20%. The comprehensive analysis showed that there was a decrease of about 10% to 25% in the ultrasonic case compared with the conventional method. It is also found that UVARM can inhibit the production of a built-up edge. With the ultrasonic vibration, the burrs on the processed surface are also reduced, and the grooves left by tool traces are shallower. Compared with conventional milling, the roughness value of the machined surface obtained by UVARM is reduced by 10% to 32%. The experimental results also show that UVARM can effectively improve the dimensional accuracy of the workpiece.

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Cusp error reduction under high speed micro/meso- scale milling with ultrasonic vibration assistance

Cited by 25 publications

References 17 publications

State-of-the-art review on vibration-assisted milling: principle, system design, and application

State-of-the-art review on vibration-assisted milling: principle, system design, and application

Hybrid micro-machining processes: A review

Experimental Study of a Novel Ultrasonic Vibration‐Assisted Structure for Radial Milling

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