Empirical study on ultrasonic assisted turn-milling

Although axial ultrasonic vibration-assisted milling (AUVAM) is promising for rapid and economical fabrication of 3D micro-texture on various surfaces, it has been a challenge to obtain micro-texture with small feature size and large height simultaneously.The mechanism and major influence factors for the formation of micro-texture by this method were explored in this study. It was found that the generation of micro-texture was mainly caused by cutting and extrusion from the flank face of the milling tool under ultrasonic vibration. Therefore, a novel 3D tool model that considered the relief angle, end cutting edge angle and the blade profile was established in simulation analysis. The good agreement between simulation and experimental results demonstrated that the influence of the flank face on the micro-texture was mainly attributed to the relief angle of the milling tool. It was the first time to report that both the height and the profile shape of the micro-texture unit were affected by the overlap and extrusion between the flank surface and the micro-texture. But this influence diminished with the increase of spindle speed. 3D sinusoid-shaped micro-texture with minimum width of 20 μm and height of 2 μm (fully reproduced the ultrasonic amplitude) was realized with the relief angle of 40 o and spindle speed of 4000 rpm. Other typical textures of weave, shell, scale and corrugation were also presented to show the effective regulation of texture patterns in AUVAM. This work provides both theoretical and practical basis for such a low-cost, efficient and controllable 3D micro-texture preparation method.

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Generation mechanism of surface micro-texture in axial ultrasonic vibration-assisted milling (AUVAM)

Zhang

Wang

Chen

et al. 2022

Int J Adv Manuf Technol

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Effect of ultrasonic-assisted turning on geometrical tolerances in Al 2024-T6

Bayat

Amini

Hadidi

2021

Materials and Manufacturing Processes

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An Investigation of Ultrasonic Vibrations Effect on Surface Roughness in Aluminum 7075 and Aisi 1045 Carbon Steel During End Milling and Side Milling Operation

2022

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Milling is one of the discontinuous machining methods which makes tools contact with workpiece continuously along with the regular change of shear force. Providing strong materials for fabricating the required pieces challenge machining and producing complex shapes. Therefore, operations intended for reducing machining forces as well as increasing the final surface smoothness are remarkably important of which using ultrasonic vibrations is one method. This study centers on ultrasonic vibration-assisted milling operation. The required ultrasonic vibrations are applied using a transducer to an AISI 1045 steel workpiece and a 7075 aluminum. Also, by using an arithmetic modal analysis simulation on the related workpiece and fixture, the designing process was performed in a way to equate the natural frequency of the whole set to that of the ultrasonic transducer. The resonant frequency obtained for the steel and aluminum workpieces was 19840 and 19757[Formula: see text]Hz, respectively, and the milling operation was done by applying ultrasonic vibrations to the workpiece. The results obtained from surface roughness measurement indicated that an increase in the ultrasonic intensity from 15[Formula: see text]W/cm2 to 22.5[Formula: see text]W/cm2 in the aluminum workpiece resulted in improved surface roughness ([Formula: see text] by 70%. In addition, an increase in the ultrasonic intensity from 15[Formula: see text]W/cm2 to 22.5[Formula: see text]W/cm2 improved the surface smoothness ([Formula: see text] by 72%. Moreover, concerning the steel workpiece while the tool is perpendicular to the direction ahead of the workpiece, it was clear that applying 22.5[Formula: see text]W/cm2 ultrasonic vibrations to the end-milled surfaces resulted in an approximate increase in the average and maximum surface smoothness by 53% and 45%, respectively. Furthermore, applying 30[Formula: see text]W/cm2 ultrasonic vibrations to face-milled surfaces, either perpendicular to or parallel to the tool, led to an approximate increase in the average and maximum surface smoothness by 35% and 25%, respectively.

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Empirical study on ultrasonic assisted turn-milling

Cited by 4 publications

References 30 publications

Generation mechanism of surface micro-texture in axial ultrasonic vibration-assisted milling (AUVAM)

Generation mechanism of surface micro-texture in axial ultrasonic vibration-assisted milling (AUVAM)

Effect of ultrasonic-assisted turning on geometrical tolerances in Al 2024-T6

An Investigation of Ultrasonic Vibrations Effect on Surface Roughness in Aluminum 7075 and Aisi 1045 Carbon Steel During End Milling and Side Milling Operation

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