Estimation of workpiece-temperature during ultrasonic-vibration assisted milling considering acoustic softening

Abstract

Ultrasonic-vibration assisted milling (UAM) process is one of the most recent advancements in the area of milling. In UAM, milling cutter vibrates with ultrasonic frequency and small amplitude during cutting. The assistance of ultrasonic-vibration during milling operation improves surface roughness, dimensional accuracy and tool life. Due to these benefits UAM finds application in precision manufacturing. Thermal aspect in machining plays a significant role in the dimensional accuracy of the products. Therefore, in this work analytical and experimental studies were carried out to model the temperature rise in workpiece during UAM process (with axial vibration). For analytical modelling, a process physics based equation was developed to predict the temperature rise in workpiece, considering acoustic softening. A setup was developed for performing UAM experiments. A statistical model was developed to estimate the temperature rise in workpiece during UAM. The predictions from physics-based and statistical models were in good agreement with experimental results.