Investigation on the Tool Wear Suppression Mechanism in Non-Resonant Vibration-Assisted Micro Milling

Zheng, Lu; Chen, Wanqun; Huo, Dehong

doi:10.3390/mi11040380

Cited by 17 publications

(8 citation statements)

References 30 publications

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“…A comprehensive study through mathematical modeling can be conducted to predict the effect of machining parameters and machining mode (VAM) which each combination affects the Ra value of the product [25]. The effect of vibration in three levels (high, medium and low) varies the wear rate of the tool and workpiece where high vibration level allows to obtain low Ra value of the material [26]. Mathema tical modeling can done through finite element analysis and recommends that low-speed machining is more applicable for VAM operational compared to high-speed machining where a high-quality end product is achieved by lowspeed machining [27].…”

Section: Introductionmentioning

confidence: 99%

Numerical modeling and experimental evaluation of machining parameters for 2-dimensions ultrasonic-assisted micro-milling at low and high-speed machining

et al. 2022

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Vibration assisted machining (VAM) is one of the hybrid machining processes for improving the machined surface quality. VAM performance is mainly influenced by the combination of machining and vibration control parameters, where surface roughness value (Ra) became the benchmarking indicator. It is difficult to determine the optimum parameter combination to produce high precision products, especially for micro-milling, due to the interconnected correlation among parameters. The benefits of high-speed machining with VAM are high material removal rate and shorter machining time than low-speed machining. VAM operation at high-speed machining is still limited due to the high possibility of chatter occurrence. Therefore, this research aims to evaluate the 2D VAM resonant performance at low-speed and high-speed machining, operated at ultrasonic vibration and amplitude below one μm. The mathematical model and experimental evaluate the vibration effect based on machining mode, amplitude, and spindle speed variation. The mathematical modelling and experiment result complement each other, where the mathematical model can characterize the effect of resonant vibration, amplitude, and spindle speed increment on the tool path trajectory. The 2D resonant vibration at the feed direction causes interrupting cutting and transforms the tool path trajectory from linear to wavy. The mathematical model and experiment result show the dominant influence of spindle speed and feed rate on the toolpath trajectory and Ra, where low spindle speed and feed rate result in better machine surface roughness. The low-speed machining with VAM results in Ra value between 0.1–0.155 μm, which is below the high-speed machining result, between 0.2–0.38 μm

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Section: Introductionmentioning

confidence: 99%

Numerical modeling and experimental evaluation of machining parameters for 2-dimensions ultrasonic-assisted micro-milling at low and high-speed machining

et al. 2022

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“…This technique overcomes limitations of existing approaches with the benefits of cost-effectiveness, high efficiency, and environmental friendliness. Engineered surface textures produced by vibration-assisted micro milling provide multifaceted performance enhancements, including reduced adhesion friction [ 20 ], smoothed lubricated sliding, upgraded wear resistance [ 21 ], controlled surface wettability [ 22 ], and tuned optical characteristics [ 23 ].…”

Section: Introductionmentioning

confidence: 99%

Theoretical and Experimental Investigation of Surface Textures in Vibration-Assisted Micro Milling

Song,

Zhang,

Jing

et al. 2024

Micromachines

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Vibration-assisted micro milling is a promising technique for fabricating engineered mi-cro-scaled surface textures. This paper presents a novel approach for theoretical modeling of three-dimensional (3D) surface textures produced by vibration-assisted micro milling. The proposed model considers the effects of tool edge geometry, minimum uncut chip thickness (MUCT), and material elastic recovery. The surface texture formation under different machining parameters is simulated and analyzed through mathematical modeling. Two typical surface morphologies can be generated: wave-type and fish scale-type textures, depending on the phase difference between tool paths. A 2-degrees-of-freedom (2-DOF) vibration stage is also developed to provide vibration along the feed and cross-feed directions during micro-milling process. Micro-milling experiments on copper were carried out to verify the ability to fabricate controlled surface textures using the vibration stage. The simulated and experimentally generated surfaces show good agreement in geometry and dimensions. This work provides an accurate analytical model for vibration-assisted micro-milling surface generation and demonstrates its feasibility for efficient, flexible texturing.

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“…In the actual cutting process, the machining path of the tool is often affected by the cutting speed, feed rate, and other processing parameters. Hence, the displacement acceleration state of the tool constantly varies, affecting the surface morphology of the workpiece [ 11 , 12 ]. Zhang et al [ 13 ] proposed a method to control the integrity of milled surfaces to explore the effect of cutting vibration on the topography of the machined surface.…”

Section: Introductionmentioning

confidence: 99%

Effect of Milling Processing Parameters on the Surface Roughness and Tool Cutting Forces of T2 Pure Copper

Lai

Kun

et al. 2023

Micromachines

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In this paper, the responses of machined surface roughness and milling tool cutting forces under the different milling processing parameters (cutting speed v, feed rate f, and axial cutting depth ap) are experimentally investigated to meet the increasing requirements for the mechanical machining of T2 pure copper. The effects of different milling processing parameters on cutting force and tool displacement acceleration are studied based on orthogonal and single-factor milling experiments. The three-dimensional morphologies of the workpieces are observed, and a white-light topography instrument measures the surface roughness. The results show that the degree of influence on Sa (surface arithmetic mean deviation) and Sq (surface root mean square deviation) from high to low level is the v, the f, and the ap. When v = 600 m/min, ap = 0.5 mm, f = 0.1 mm/r, Sa and Sq are 1.80 μm and 2.25 μm, respectively. The cutting forces in the three directions negatively correlate with increased cutting speed; when v = 600 m/min, Fx reaches its lowest value. In contrast, an increase in the feed rate and the axial cutting depth significantly increases Fx. The tool displacement acceleration amplitudes demonstrate a positive relationship. Variation of the tool displacement acceleration states leads to the different microstructure of the machined surfaces. Therefore, selecting the appropriate milling processing parameters has a positive effect on reducing the tool displacement acceleration, improving the machined surface quality of T2 pure copper, and extending the tool’s life. The optimal milling processing parameters in this paper are the v = 600 m/min, ap = 0.5 mm, and f = 0.1 mm/r.

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Investigation on the Tool Wear Suppression Mechanism in Non-Resonant Vibration-Assisted Micro Milling

Cited by 17 publications

References 30 publications

Numerical modeling and experimental evaluation of machining parameters for 2-dimensions ultrasonic-assisted micro-milling at low and high-speed machining

Numerical modeling and experimental evaluation of machining parameters for 2-dimensions ultrasonic-assisted micro-milling at low and high-speed machining

Theoretical and Experimental Investigation of Surface Textures in Vibration-Assisted Micro Milling

Effect of Milling Processing Parameters on the Surface Roughness and Tool Cutting Forces of T2 Pure Copper

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