Modelling and experimental investigation on textured surface generation in vibration-assisted micro-milling

Abstract

This paper investigates the textured surface generation mechanism in vibration-assisted micro milling through modelling and experimental approaches. To decouple the effects of tool geometry and kinematics of vibration-assisted milling, a surface generation model based on homogenous matrices transformation is proposed. On this basis, series of simulations are performed to provide insights into the effects of various vibration parameters (frequency, amplitude and phase difference) on the generation mechanism of typical textured surfaces in 1D and 2D vibration-assisted milling. Furthermore, the wettability tests are performed on the machined surfaces with various surface texture topographies. The fish-scale textured surfaces are found to exhibit better wettability than those with wavy-structure. The results indicate that vibration-assisted milling is an effective method to generate certain surface textures with controllable wettability.

Micro milling process modeling: a review

“…The influence of the tool wear on surface roughness was investigated and enlargement of tool edge radius was found to be one of the wear modes in micro machining as it affects the machining mechanism. Chen et al [31,34] FEM, experimental Aluminum 6061 Since the machining system is not a rigid body system, the cutting force generated during milling could induce the relative displacement between tool and workpiece, combine word displacement. Liu et al [39] Experimental Aluminum 6061…”

“…By using abovementioned inputs, authors generated 3D surface topography and validated it with several experimental results, as presented in Figure 8. Similarly, Chen et al [34] developed the textured surface generation mechanism in vibration-assisted micro milling through modelling and experimental approaches. A surface generation model decouples the effects of tool geometry and kinematics of vibration-assisted milling.…”

A review on micro-milling: recent advances and future trends

“…Hybrid micro-milling technologies try to fuse the advantages of the mechanical micro-milling and another advanced technology to-more or less-increase (i)-(iv) or decrease (v)-(vii) properties of the process [285]. Ultrasonic vibration-assisted micro-machining is a promising novel technology, which is able to decrease the cutting force, burr formation and surface roughness, compared to the mechanical micro-milling [236,[286][287][288]. Furthermore, the wettability of the micro-machined surfaces can be more advantageous, if the cutting tool or the workpiece is vibrated in an optimised ultrasonic frequency.…”

The Influence of Flexure Variation to Vibration-Assisted Micro-Milling Device by Using Finite Element Analysis

“…During its application, the tool path, which is a linear path, becomes zig-zag or elliptical during the machining process. [7][8][9] . It will cause interrupting cutting that ignites an additional cooling period.…”