Development of Multi-Axis Cutting Method Using Non-Rotational Tool with Ultrasonic Vibration

Abstract

In recent years, rotary tools such as ball and flat end mills are widely used to produce dies and parts. Machining using rotary tools shortens cutting time, raising efficiency and discharging cutting chips cleanly, but leaves the machined face rough due to arc-shaped rotation marks. The radius of rotation for the location of the cutting edge from the tool's center axis is non-consistent, varying tool edge cutting speed and direction, making it difficult to leave surface roughness uniform. Removing unfinished areas and reducing final machined face surface roughness to the submicron level thus requires secondary finishing, which conventionally relies on hand polishing by a skilled worker. We developed extremely small cut-in machining using a non-rotational tool to establish final die machine finishing. We discuss machining tests with ultrasonic vibration added to machine prehardened steel, used mainly as a die material, to a mirror finish using a nonrotational diamond tool, and evaluate its usefulness.