Abstract
Two advanced machining methods such as thermally enhanced machining and ultrasonic-assisted machining are recently considered in many studies. In this article, a new hybrid milling process is presented by gathering the characteristics of these two methods. In order to determine the axial depth of cut and engagement in the process, three-dimensional thermal finite-element analysis is applied to determine the dimensions of softened materials. Finite-element modal analysis is used to determine the dimensions and clamping state of the workpiece while cutting area has the highest vibration amplitude. Full factorial experimental design is applied to investigate the effect of hybrid machining parameters on the surface roughness and tool wear. Tool flank wear was investigated under the condition of constant cutting speed during different period of times. Hybrid milling process with an amplitude of 6 µm and a temperature of 900°C creates a surface with 42% lower roughness in comparison to conventional milling in feed 0.08 mm/tooth. In a study of tool flank wear, the results show that application of TEUAM decreases flank wear at least 16% in comparison to all other processes.
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