Study on the Mechanism of Burr Formation by Simulation and Experiment in Ultrasonic Vibration-Assisted Micromilling

Abstract

Due to the strong plasticity of Inconel 718 and the significant size effect of micromachining, a large number of burrs will be produced in traditional processing. The addition of ultrasonic vibration during machining can reduce the burr problem. The mechanism of burr generation in traditional micromilling (TMM) and ultrasonic vibration-assisted micromilling (UVAMM) was analyzed by simulation, and verified by corresponding experiments. It is found that applying high-frequency ultrasonic vibration in the milling feed direction can reduce cutting temperature and cutting force, improve chip breaking ability, and reduce burr formation. When the cutting thickness will reach the minimum cutting thickness hmin, the chip will start to form. When A/ƒz > 1/2, the tracks of the two tool heads start to cut, and the chips are not continuous. Some of the best burr suppression effects were achieved under conditions of low cutting speed (Vc), feed per tooth (ƒz), and large amplitude (A). When A is 6 μm, the size and quantity of burr is the smallest. When ƒz reaches 6 μm, large continuous burrs appear at the top of the groove. The experimental results further confirm the accuracy of the simulation results and provide parameter reference.

Research Status and Prospect of Ultrasonic Vibration and Minimum Quantity Lubrication Processing of Nickel-based Alloys

“…However, an amplitude of more than 12 μm will greatly increase the cutting force and aggravate the wear of the drill bit. When the ultrasonic vibration amplitude is 6 μm, the size and number of burrs are the smallest [34].…”

“…Lower cutting speed and feed per tooth have the best effect on burr suppression. When the feed rate per tooth was 6 μm, a large number of continuous burrs appeared at the top of the groove [34]. The faster the milling speed, the weaker the intermittent separation cutting characteristics, and the less easily the chips are broken.…”

Creation of an Aluminum Alloy Template with a Surface Structure by Micro-Milling for Subsequent Replication of the Microstructure to Achieve Hydrophobicity

“…Using multi-axis control, complex contours can be machined with excellent continuity of different pattern structures. Technological stability and relatively simple process control principles allow the use of micro-milling in the fields of medicine (production of chips for insulin pumps, various parts of implants, and dentistry), electrical engineering, and watchmaking [13][14][15][16][17][18][19][20][21][22][23][24][25].…”

Cutting-Force Modeling Study on Vibration-Assisted Micro-Milling of Bone Materials

“…Therefore, bone-cutting surgery can be regarded as a precision machining process. As an essential processing method, micro-milling has the advantages of high material-removal rate [ 3 ] and good surface quality so that it can be used in bone-material removal surgery. However, the mechanical load and temperature in the micro-milling process have a great influence on the milling of bone materials [ 4 ].…”