The Effect of One Directional Ultrasonic Vibration Assistance in High Speed Meso-Scale Milling Process

Abstract:

One-directional ultrasonic vibration assisted milling system is designed and its performance is investigated in terms of machined surface quality under 135,000 rpm. The ultrasonic vibration generator excites the workpiece with a frequency around 40 kHz and amplitude of a few micro meters. The milling tool’s cutting speed is controlled by an air-bearing spindle system. Both feed-directional and cross-feed directional ultrasonic vibration assistance are considered in order to understand the mechanism of ultrasonic vibration assistance for surface roughness generation. A comparison is done on a milled surface which is generated with and without ultrasonic vibration assistance. The experimental results show that ultrasonic vibration assistance can improve the machined surface quality which depended on the cutting edge radius and the feed per tooth.

• Periodical: Key Engineering Materials (Volumes 447-448)
• Pages: 41-45
• DOI: https://doi.org/10.4028/www.scientific.net/KEM.447-448.41
• Online since: September 2010
• Authors: Jeong Hoon Ko, Kah Chuan Shaw, Han Kwang Chua, Rong Ming Lin
• Keywords: Machined Surface Quality, Milling, Ultrasonic Vibration Assistance

References

[1] D.E. Brehl and T.A. Dow: Review of vibration-assisted machining, Precision Engineering, vol. 32, (2008), pp.153-172.

DOI: 10.1016/j.precisioneng.2007.08.003

[2] E. Shamoto and T. Moriwaki: Ultrasonic diamond cutting of hardened steel by applying elliptical vibration cutting, Annals of the CIRP Ann, vol. 48, (1999), pp.441-444.

DOI: 10.1016/s0007-8506(07)63222-3

[3] M. Xiao, K. Sato, S. Karube, and T. Soutome: The effect of tool nose radius in ultrasonic vibration cutting of hard metal, International Journal of Machine Tools & Manufacture, vol. 43, (2003), pp.1375-1382.

DOI: 10.1016/s0890-6955(03)00129-9

[4] C. Nath, M. Rahman, and K.S. Neo: A study on ultrasonic elliptical vibration cutting of tungsten carbide, Journal of Materials Processing Technology , vol. 209, (2009), pp.4459-4464.

DOI: 10.1016/j.jmatprotec.2008.10.047

[5] E. Shamoto and T. Moriwaki: Study on elliptical vibration cutting, Annals of the CIRP, vol. 43, no. 1, (1994), pp.35-38.

DOI: 10.1016/s0007-8506(07)62158-1

[6] G. L. Chern and Y. C. Chang: Using two-dimensional vibration cutting for micro-milling, International Journal of Machine Tools & Manufacture, vol. 46, (2006 ) pp.659-666.

DOI: 10.1016/j.ijmachtools.2005.07.006

[7] T. Moriwaki, E. Shamoto, Y.C. Song, and S. Kohda: Development of a elliptical vibration milling machine, CIRP Annals - Manufacturing Technology, vol. 53, (2004), pp.341-344.

DOI: 10.1016/s0007-8506(07)60712-4

[8] J. H. Ko, K. C. Shaw, I. P. Girsang, R. Vinay, J. S. Dhupia and: Surface quality assessment for micro-milling applications under various cutting conditions, IMSEC - International Conf. on Manufac. Sci. and Engg., (2009).

[9] W. S. Yun, J. H. Ko, D. W. Cho, and K. F. Ehmann: Development of a Virtual Machining System, Part 2: Prediction and Analysis of a Machined Surface Error, International Journal of Machine Tools and Manufacture, Vol. 42, (2002), pp.1607-1615.

DOI: 10.1016/s0890-6955(02)00138-4

[10] X. Liu, R.E. DeVor, S.G. Kapoor: An analytical model for the prediction of minimum chip thickness in micromachining. Journal of Manufacturing Science and Engineering, Transactions of the ASME, Vol. 128, (2006), pp.474-481.

DOI: 10.1115/1.2162905