Feed-direction ultrasonic vibration−assisted milling surface texture formation

Abstract

The formation mechanism of surface texture for feed-direction ultrasonic vibration assisted milling was investigated in this study by establishing a kinematic model and a pressing model of ultrasonic vibration assisted milling (UVAM). The kinematic model showed that the cutter tip which was supposed to be totally sharp produced closed scratches by crossed trajectories. The variation trends of the interval for closed textures were of sin function. A comparative experiment was carried out by UVAM and conventional milling. A dividing line close to the X coordinate divides the surface feature into two parts. The pressing model showed that the tool minor cutting edge left clear traces with certain width because of the tool minor cutting edge angle. Scratches by tool minor cutting edge were intermittent and regularly varied when feed-direction vibration was introduced. All the surface feature changes are in the radial direction and the trajectory intersections shall always be the scratch grooves or ridges. The ratio between ultrasonic vibration frequency and spindle speed, tool radius and the located cutter Downloaded by [University of Sussex Library] at 02:03 28 June 2016 2 rotation angle affected the changing rule of scratches by tool minor cutting edge. The analytical models and the experimental results proved to each other reasonable.

Research on Homogenization and Surface Integrity of Ti-6Al-4V Alloy by Longitudinal-Torsional Coupled Ultrasonic Vibration Ball-End Milling

“…Figure 6 can clear illustrate the difference about cutting force both in the UVAM and CM process. In the UVAM process, the cutting force in 20 s is much lower than that by CM process both in the maximum force value and the average force value [18]. Ultrasonic vibration cutting force is uniform in a short period occupying whole cutting data time, at the same time, the cutting force in CM process is changing slowly and much higher than the ultrasonic one.…”

“…Tao et al proposed a kinematic model and a pressing model for the formation mechanism of surface texture for feed-direction ultrasonic vibration assisted milling . But this research had less pay attention on the overlapping machining area [18]. Applying ultrasonic vibration in the feed direction [19][20] and main shaft axial direction [21] could change the surface quality via matching different cutting parameters.…”

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

“…18 Cross-cut metallography slides for: a conventionally and b 20 kHz ultrasonically machined coupons Fig. 19 Carp surface and SEM photo of the VAMilling surface [95] length) and consequently reducing tool contact length, is recognized as one of the main reasons to reduce the cutting force [87]. During the elliptical motion of tool tip in VAM, the average force is reduced and this reduced tool cutting force has also been shown to reduce chatter [88] on the surface produced.…”

“…There is an emerging trend to obtain biomimetic surface texture and certain surface performance through VAM. Tao et al [95] produced the squamous surface by VAMilling as shown in Fig. 19.…”

Modelling and experimental investigation on textured surface generation in vibration-assisted micro-milling

“…In this model, although the tool profile was mapped along tool path to consider the effects of multiple tool engagements on surface generation, the effects of the tool geometry was still overlooked. Tao et al (2017) also analyzed the influence of tool parameters on surface generation, they simplified the tool cutting edge as a sharp one, to simple the simulation process and reduce the computation time, but it reduces the accuracy of the surface texture simulation. Recently, Börner et al (2018) proposed an improved modelling model for textured surface generation in VAMILL.…”