Tool–workpiece separation characteristic and surface generation in ultrasonic assisted milling

Abstract

Ultrasonic assisted machining is an eco-friendly surface texture fabrication method with low machining cost, high-accuracy precision, and efficiency. This study analyzes the surface texture formation in feed direction ultrasonic vibration assisted milling (FUVAM) and elliptical ultrasonic vibration assisted milling (EUVAM). The trajectories of the single and adjacent tool tips in FUVAM are analyzed. Furthermore, the tool–workpiece separation mechanism in EUVAM is discussed. Moreover, a 3D surface topography model of EUVAM is applied to study the influences of machining parameters on the ultrasonic machining topography. The experiments of conventional milling (CM) and EUVAM are carried out and different types of surface textures are successfully fabricated on Ti-6Al-4V using EUVAM. The results of the response surface indicate that the surface roughness shows an increasing trend with higher spindle speed, but decreases with improved feed speed and cutting depth. Compared with CM, the chips generated in EUVAM have the characteristics of small width and low bending degree. This work is expected to provide some guidance for the selection of machining and vibration parameters during ultrasonic assisted milling.

Keywords:

• Ultrasonic assisted milling
• surface texture
• tool–workpiece contact rate
• Ti-6Al-4V
• tool wear

Disclosure Statement

The authors declare that they have no known competing financial interests or personal relationships that could have appeared to influence the work reported in this article.

Additional information

Funding

This work was supported by the National Natural Science Foundation of China [51975112] and Fundamental Research Funds for Central Universities [N2203011].