Experimental investigations on effects of frequency in ultrasonically-assisted end-milling of AISI 316L: A feasibility study

Maurotto, Agostino; Wickramarachchi, Chandula T.

doi:10.1016/j.ultras.2015.10.012

Cited by 67 publications

(28 citation statements)

References 28 publications

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“…Tsai et al [84] investigated the machining of hard mold steel by ultrasonic assisted end milling, and found that a positive rake angle and a large helix angle gave improved surface finish. Maurotto and Wickramarachchi [85] investigated the effects of frequency in ultrasonically assisted end milling on grain sizes of AISI 316L. They found that grain sizes appeared comparable with conventional milling and there was no sign of grain rotations, grain refinements, or strongly deformed areas indicative of significant machining abuse, as shown in Fig.…”

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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“…This is because the ratio of the vibration frequency f to spindle speed n decreased as cutting speeds went up. It means that the tool-workpiece contact ratio (TWCR) escalates as cutting speeds increase and the engagement time between the tool and the workpiece in single vibration cycle lasts longer at higher cutting speeds [19]. The excellent cooling and lubrication effects brought by separation characteristic in HRUEM will be weakened at a higher value of TWCR and more heat accumulates in the cutting zone.…”

Section: Tool Lifementioning

confidence: 99%

“…As an intermittent cutting method, ultrasonic vibration machining (UAM) has been widely discussed for its ability to open the tool-workpiece contact area intermittently. As one of the typical UAM processes, the ultrasonic-assisted milling technique has been widely applied to machine difficult-to-cut alloys for its superiority in expanding tool life, lowering cutting force and delivering better surface quality [18][19][20][21][22][23][24]. In order to obtain the intermittent cutting mode between the tool and the workpiece in UAM, its relative velocity in cutting direction should be controlled as the opposite to the tool rotation direction periodically.…”

Section: Introductionmentioning

confidence: 99%

High-Speed Rotary Ultrasonic Elliptical Milling of Ti-6Al-4V Using High-Pressure Coolant

Zhang

Guo³

et al. 2020

Metals

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High-speed rotary ultrasonic elliptical milling (HRUEM), as a novel ultrasonic vibration cutting method, has been introduced in milling the alloy Ti-6Al-4V. The application of ultrasonic vibration in high-speed milling can help open the cutting contact area intermittently. New cutting effects will happen with full use of the separation effect brought by ultrasonic vibration and the cooling effect brought by a high-pressure coolant (HPC). On the basis of that, this paper firstly introduces HPC into HRUEM of Ti-6Al-4V in the open literature and analyzes the tool-workpiece separation cooling mechanism in HRUEM, including kinematic analysis of tool tip trajectories, tool-workpiece separation principles and high-pressure coolant effects. We have conducted a comprehensive experimental study and the results show when HPC is increased to 200 bar, compared to conventional milling (CM), the tool life in HUREM can be extended by 6.6 times at 80 m/min, 4.2 times at 120 m/min and 2.4 times at 160 m/min. The maximum material removal volume (MRV) for a given new end mill in HRUEM is increased by 657% approximately. When the cutting speed is 80 m/min, the cutting temperature of the workpiece in HRUEM is reduced by 24.1% compared to that of CM. By applying the combination of HPC and tool-workpiece periodic separation, we can significantly enhance the cooling and lubrication efficiency in HRUEM and also inhibit the tool wear mode of adhesive wear typically occurred in CM.

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“…This may be due to the low thermal conductivity of titanium alloy lead to high temperature near cutting point, and under UVAM condition, the periodic separation between tool and workpiece can be beneficial to the heat dissipation. [17][18][19] Figure 10 gives the surface roughness of the slot bottom of 6061T6 and TC4 with different feed rates under CM and UVAM condition. Figures 11-13 are slot bottom images for 6061T6 and Figures 14-16 for TC4 under different milling conditions.…”

Section: Milling Forcementioning

confidence: 99%

Machinablity improvement with ultrasonic vibration–assisted micro-milling

Han

2018

Advances in Mechanical Engineering

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An ultrasonic vibration-assisted micro-milling with horizontal vibration of workpiece is investigated in this article. A vibration platform with maximum amplitude of 15 mm based on universal ball support structure is designed and built by our group. Titanium alloy TC4 and aluminum alloy 6061T6 were chosen as workpiece material. Series of slot-milling experiments were conducted with and without vibration at different amplitudes and feed rates to explore the effects of vibration on the micro-milling. Experiment results showed that ultrasonic vibration can effectively reduce milling force by 12% and 17%, respectively, for aluminum alloy 6061T6 and titanium alloy TC4 compared with that of conventional milling and hence leading to a better machining accuracy and longer tool life. Furthermore, the effect of ultrasonic vibration on titanium alloy is much more obvious. The topographies of machined surfaces also showed that ultrasonic vibration can reduce surface defects and machining marks and thus improve the surface quality for both 6061T6 and TC4. Besides these, it is worth to be noted that ultrasonic vibration leads the size effect point appear at much lower feed rate than conventional milling, which means vibration brings a change to machining mechanism and delays the appearance of micro-milling.

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Experimental investigations on effects of frequency in ultrasonically-assisted end-milling of AISI 316L: A feasibility study

Cited by 67 publications

References 28 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

High-Speed Rotary Ultrasonic Elliptical Milling of Ti-6Al-4V Using High-Pressure Coolant

Machinablity improvement with ultrasonic vibration–assisted micro-milling

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