On unsteady-cutting state material separation and dead metal zone modeling considering chip fracture

Song, Bowen; Jing, Xiubing; Yang, He; Zheng, Shuxian; Zhang, Dawei; Li, Huaizhong

doi:10.1016/j.jmapro.2023.10.072

Cited by 2 publications

(1 citation statement)

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“…For many years, micromachining technology has dedicated significant efforts to investigating the microscopic scale material removal process [ 10 , 11 ]. Recently, vibration-assisted micro machining has arisen as a promising approach for accurate and flexible surface texturing [ 12 , 13 , 14 ].…”

Section: Introductionmentioning

confidence: 99%

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

Song,

Zhang,

Jing

et al. 2024

Micromachines

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Vibration-assisted micro milling is a promising technique for fabricating engineered mi-cro-scaled surface textures. This paper presents a novel approach for theoretical modeling of three-dimensional (3D) surface textures produced by vibration-assisted micro milling. The proposed model considers the effects of tool edge geometry, minimum uncut chip thickness (MUCT), and material elastic recovery. The surface texture formation under different machining parameters is simulated and analyzed through mathematical modeling. Two typical surface morphologies can be generated: wave-type and fish scale-type textures, depending on the phase difference between tool paths. A 2-degrees-of-freedom (2-DOF) vibration stage is also developed to provide vibration along the feed and cross-feed directions during micro-milling process. Micro-milling experiments on copper were carried out to verify the ability to fabricate controlled surface textures using the vibration stage. The simulated and experimentally generated surfaces show good agreement in geometry and dimensions. This work provides an accurate analytical model for vibration-assisted micro-milling surface generation and demonstrates its feasibility for efficient, flexible texturing.

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