Surface Quality Improvement in Meso-Scale Milling with Spindle Axial Directional Ultrasonic Vibration Assistance

Abstract:

So far, the industrial application of ultrasonic vibration assistance has been successful in continuous machining process such as turning process where ultrasonic vibration velocity is much higher than cutting velocity. Recently, vibration assistance has been experimentally investigated to the intermittent milling process mainly for feed and cross- feed directions. This paper focuses on the effect of ultrasonic vibration assistance in spindle axial direction for improvement of machined surface. With the designed ultrasonic vibration assisted milling process with 39.7 kHz and a few micro-meter amplitudes, workpiece vibrates along spindle axial direction while different RPMs and feed rates are applied. The axial directional vibration assistance acts as additional cutting motion which further reduces the leftover surface error. Experimental results validate that surface roughness can be improved from 20 % to 65 % for the tested conditions. Apparently chatter marks of the milling process are reduced with the help of the axial ultrasonic vibration assistance.

• Periodical: Advanced Materials Research (Volume 565)
• Pages: 508-513
• DOI: https://doi.org/10.4028/www.scientific.net/AMR.565.508
• Online since: September 2012
• Authors: Jeong Hoon Ko, Kah Chuan Shaw, Sha Wei Tan, Rong Ming Lin
• Keywords: Meso-Scale Milling Process, Surface Quality, Ultrasonic Vibration Assistance

References

[1] D.E. Brehl and T.A. Dow: Precision Engineering Vol. 32 (2008), p.153.

[2] E. Shamoto and T. Moriwaki: CIRP Annals - Manufacturing Technology Vol. 48(1999), p.441.

[3] M. Xiao, K. Sato, S. Karube, and T. Soutome: International Journal of Machine Tools & Manufacture Vol. 43 (2003), p.1375.

[4] C. Nath, M. Rahman and K.S. Neo: Journal of Materials Processing Technology Vol. 209 (2009) , p.4459.

[5] E. Shamoto and T. Moriwaki: Annals of the CIRP Vol. 43, (1994), p.35.

[6] E. Shamoto T. Moriwaki Y.C. Song and S. Kohda: CIRP Annals - Manufacturing Technology Vol. 53 (2004), p.341.

[7] G.L. Chern and Y.C. Chang: International Journal of Machine Tools & Manufacture Vol. 46 (2006), p.659.

[8] X. Shen, J. Zhang and X. Dongliang: International Journal of Advanced Manufacturing Technology, Vol. 58 (2011), p.553.

[9] J.H. Ko, K.C. Shaw, H.K. Chua and R.M. Lin: International Journal of Precision Engineering and Manufacturing Vol. 12 (2011), p.15.

[10] J.H. Ko and K.C. Shaw: International Journal of Precision Engineering and Manufacturing Vol. 10 (2009) p.19.

[11] J.H. Ko and Y. Altitntas: Journal of Manufacturing Science and Engineering Vol. 129 (2007) p.32.

[12] J.H. Ko and Y. Altintas: International Journal of Machine Tools and Manufacture Vol. 47 (2007), p.1351.

[13] Y. Altintas and J. H. Ko: CIRP Annals Vol. 55 (2006), p.361.

[14] S.M. Son, H.S. Lim, and J.H. Ahn: International Journal of Machine Tools and Manufacture Vol. 45 (2005), p.529.

[15] J.H. Ko, I.P. Girsang, R. Vinay, J.S. Dhupia, and K.C. Shaw: IMSEC - International Conference on Manufacturing Science and Engineering, (2009) pp.333-341.

[16] X. Liu R.E. DeVor and S.G. Kapoor: Journal of Manufacturing Science and Engineering, Vol. 128 (2006) p.474.

[17] H. Li, X. Lai, C. Li, J. Feng, and J. Ni: Journal of Micromechanics and Micro-engineering Vol. 18 (2008), p.1.

[18] J.H. Ko: International Journal of Precision Engineering and Manufacturing Vol. 7 (2006), p.8.

[19] J.H. Ko, and D.W. Cho : Transactions of the ASME, Journal of Manufacturing Science and Engineering Vol. 127, (2005), p.1.

[20] J.H. Ko and D.W. Cho: International Journal of Advanced Manufacturing Technology Vol. 26 (2005), p.1211.