Generation of Textured Surfaces by Vibration-Assisted Ball-End Milling

Abstract

Textured surfaces have been widely applied in many fields due to their excellent functional performances. Although several micro-scale surface texturing techniques have been used to fabricate surface textures, most are either very expensive, have material limitations, or lack flexibility. In this study, a novel textured surface generation method using vibration-assisted ball-end milling with a non-resonant vibrator is proposed. Firstly, the configuration of the vibration-assisted ball-end milling system is introduced. Then, the trajectories of the cutting edges are modeled and analyzed. Furthermore, an analysis of a non-resonant vibrator is conducted. Finally, surface texture machining experiments are conducted, and the feasibility of the proposed vibration-assisted ball-end milling method for surface texture fabrication is verified.

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

“…Lv et al [ 29 ] developed a 3D vibration-assisted milling model for generating various structured surfaces by employing orthogonal spiral and multi-body kinematics theories. Yuan et al [ 30 ] presented a vibration-assisted ball-end milling method for generating various surface textures using a non-resonant vibrator. Their model considered the tool trajectory in the vibration-assisted ball-end milling process, the quantitative relationships between the generated dimple geometric parameters, and the cutting and vibration condition.…”

Simulation and Experimental Study of Non-Resonant Vibration-Assisted Lapping of SiCp/Al

“…The ultrasonic vibration device usually works near the resonance point, and its high-frequency vibration will produce much heat, affecting the processing effect of SiCp/Al composite materials [ 19 , 20 ]. In addition, resonant ultrasonic vibration suffers from many limitations in vibration frequency and amplitude adjustment, which makes it difficult to achieve a wide range of free adjustments, and the selection of processing parameters will be limited [ 21 , 22 ].…”