Experimental study on ultrasonic assisted milling effect on blade distortion

Abstract

Distortion in milling is a prevalent issue that can arise during material machining. It stems from the forces exerted by the cutting tool on the machined material, resulting in uneven material removal and subsequent warping of the parts. The distortion can be prevented with proper cutting speed, feed rate, and tool selection. Ultrasonic-Assisted Milling (UAM) mitigates distortion in milling processes by optimizing cutting conditions. This machining technique employs high-frequency vibrations to efficiently remove material from a workpiece. In this study, 18 tests according to a full factorial design experiment were used to investigate cutting force and distortion in two modes of conventional milling and ultrasonic-assisted milling. Our findings reveal a direct correlation between cutting force and distortion in UAM. Specifically, UAM exhibited a significant reduction of approximately 28.4% in cutting force compared to conventional milling (CM). Furthermore, distortion in UAM was diminished by about 34.06%. Additionally, a noteworthy improvement of 28.4% in surface roughness was observed. These results collectively help produce accurate workpieces and ensure the production of undamaged and warp-free parts.