The Role of Dry Aero-acoustical Lubrication and Material Softening in Ultrasonically Assisted Milling of Difficult-to-Cut AISI 304 Steels

Abstract

A recent and promising technique in advanced material processing techniques is the use of ultrasonic assistance in almost all cutting, forming and shaping processes. Optimizing manufacturing costs through reducing process forces and tool wears, improving machinability through enhancing surface finish and quality with minimal production time and energy, and delivering products with prolonged service life are some of the most important features of the vibration assisted manufacturing methods.To study the effect of ultrasonic vibrations on the milling process of the stainless steels, a series of experiments was designed and then implemented on a difficult-to-machine material. The result of the surface roughness and the cutting force tests has been comprised with and without processing by ultrasonic assistance. Experiments prove that under ultrasonic assistance, cutting forces are reduced, surface quality is improved and in all, a better machinability is achieved. It is concluded that dry aero-acoustical lubrication conditions and materials softening are of crucial importance in the machinability of difficult-to-cut AISI 304 materials.

An Investigation on the Enhanced Wear Behavior of Ultrasonically Stirred Cast A356/SiO2np Nano-composites

“…The transducer with such configurations can also be used in some other manufacturing processes, including powder consolidations, machining, welding, etc. [44][45][46][47]. To protect the transducer, it was placed inside metal housing and the concentrator was placed outside the mentioned housing.…”

Energy field-assisted high-speed dry milling green machining technology for difficult-to-machine metal materials

“…Scholars have already considered the simultaneous influence of the axial vibration and feed vibration of workpieces during the machining process. Razfar et al [182] studied the UVAM of high-strength steel. First, a UVAM experiment was conducted on AISI 1020 steel based on one-dimensional axial longitudinal vibration (workpiece vibration) when f was set to 20 kHz and the power was 250 W. Then, the effects of v c , f z , α p , and ultrasonic treatment on the surface roughness were investigated, and the results showed that the surface roughness of CM and UVAM exhibited similar curves and increased with increasing f z and v c .…”

“…First, a UVAM experiment was conducted on AISI 1020 steel based on one-dimensional axial longitudinal vibration (workpiece vibration) when f was set to 20 kHz and the power was 250 W. Then, the effects of v c , f z , α p , and ultrasonic treatment on the surface roughness were investigated, and the results showed that the surface roughness of CM and UVAM exhibited similar curves and increased with increasing f z and v c . Compared to CM, the average surface roughness after UVAM increased by 12.9% [182]. Second, based on the same vibration mode, a power of 220 W was used to conduct UVAM of AISI 304 steel.…”

Experimental Investigation on Axial Ultrasonic Vibration Assisted Milling of Cr12MoV

“…Literature [18] carried out a comprehensive experiment on surface integrity in rotary ultrasonic elliptical end milling of Ti6Al4V with various vibration amplitudes and cutting speeds, and the results showed that surface roughness was be risen with increase of cutting speed and vibration amplitude. The ultrasonic vibration cutting technology was applied to the milling process of AISI304 steel [19], and the test results showed that the milling force and the surface roughness were reduced. The effects of ultrasonic vibration milling of 718 nickel alloy was investigated on material surface integrity, tool wear, milling forces, and fatigue resistance [20].…”