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Residual stresses in feed direction and normal to feed direction for different vibration amplitudes in LVAM; left: bottom surface for slot milling; right: side surface for peripheral milling
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In vibration-assisted milling (VAM), an additional high-frequency oscillation is superimposed on the kinematics of a conventional machining process. This generates oscillations of the cutting edge in the range of a few micrometers, thereby causing a high-frequency change in the cutting speed and/or the feed. Consequently, a reduction of cutting for...
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Citations
... 29,30 Furthermore, the bone LTVUM reduces the effects of bone anisotropy and cutting speed, while enhancing the impacts of feed rate. 29 Rinck et al. 31,32 found that the Ti-6Al-4V of LTVUM significantly reduces cutting force, improves cutting surface smoothness, and it has a better cutting performance compared to longitudinal assisted milling. Besides, Niu et al. 33 investigated the tool edge trajectory and cutting force of LTVUM, and reported that the cutting forces of the x and y directions decreased by 24.8% and 29.9%, respectively. ...
Multi-tooth milling cutters have the advantages of minimal surface damages and low cutting forces and are widely used in composite materials milling such as carbon fiber and wood. Cortical bone is a composite biomaterial similar to carbon fiber and wood; however, the cutting performance of multi-tooth milling cutters on bone cutting is unclear. Here, this paper proposes a multi-tooth milling cutter longitudinal torsional ultrasonic vibration assisted milling (LTVUM) method for cortical bone low damage cutting. The cutting performance of sinusoidal and corn edge cutters for cortical bone LTVUM was studied, and its material removal mechanisms were also established. The results indicated that the multi-tooth milling cutter has a smaller average cutting force, and suppressing the chip burrs and tearing damages. Compared to straight edge cutter, the resultant cutting forces of sinusoidal and corn edge cutters are decreased by 52.58%–61.01% and 45.60%−65.96%. The reason is that the secondary cutting edge of multi-tooth cutter can participate in cutting, reducing the tool squeeze interference. This work provides experimental guidance for the application of multi-tooth milling cutters LTVUM in bone cutting.
... Comparative analysis between LTUVAM and LUVAM in milling operations for Ti-6Al-4V was undertaken by Rinck et al., revealing that LTUVAM led to a reduction of 57 % in cutting forces, surpassing the 44.3 % reduction achieved by LUVAM when compared to CM. Additionally, it was found that LTUVAM resulted in lower tool wear compared to LUVAM [12]. ...
... Consequently, this mode of operation facilitates the smoothing of the surface without leaving deep traces, creating micro-peaks on the surface and enabling lower surface roughness values compared to vibrations in other directions. Existing literature also supports that multi-axial UVAM yields lower surface roughness values compared to single-axis UVAM [12]. The lower surface roughness values obtained in Z-UVAM as compared to X-UVAM can be explained as follows: The periodic separations generated by ultrasonic vibrations applied along the feed direction in X-UVAM during the cutting process give rise to 'ironing', 'dressing' and 'rubbing' action between the cutting tool and the workpiece on the bottom surface [63]. ...
Ti-6Al-4V offers a balance of good strength with lightweight properties. Yet, Ti-6Al-4V poses machining challenges, including low thermal conductivity, chemical adhesion to cutting tools, and chip removal difficulties. To improve machining efficiency, Ultrasonic Vibration-Assisted Machining (UVAM) has emerged as a promising approach. UVAM has demonstrated reduced tool wear, cutting forces, and improved surface quality compared to Conventional Machining (CM). Additionally, Minimum Quantity Lubrication (MQL) methods offer sustainable coolant alternatives, with recent research focusing on Nanofluid-MQL (NMQL) and Hybrid Nanofluid-MQL (HNMQL) for enhanced performance. Although there exists a body of literature showcasing the promising effects of UVAM and MQL methods individually, comprehensive investigations into the synergistic effects of these methodologies remain limited. This study addresses these critical research gaps by conducting a systematic examination of combined application of multi-axial UVAM and HNMQL. Specifically, it delves into the comparison of different vibration directions within UVAM, evaluates the effectiveness of UVAM when combined with cutting fluids incorporating Al2O3 and CuO nanoparticles in NMQLs and HNMQLs, and contrasts these novel approaches with conventional machining methods. The study unfolds in three distinct stages. The first stage examines the ultrasonic cutting mechanism and its combined application with the MQL technique. In the second stage, the study investigates the physical properties of the cutting fluids, including contact angle and surface tension. The final stage encompasses slot milling operations, where an array of parameters such as cutting forces, surface roughness, surface topography, surface texture, and the occurrence of burr formations are rigorously analyzed. The results demonstrate that the combination of multi-axial UVAM with HNMQL yields substantial advantages over traditional machining methods. Notably, it leads to a remarkable reduction in cutting forces (up to 37.6 %) and surface roughness (up to 37.4 %). Additionally, this combination engenders the production of highly homogeneous and uniform surface textures, characterized by minimal surface defects and a significantly diminished occurrence of burr formations. These findings underscore the potential of multi-axial UVAM combined with HNMQL as a promising approach in enhancing the machining of Ti-6Al-4V, thus offering a pathway to enhance the efficiency and precision of aerospace component manufacturing processes.
... US milling allows a further reduction of the stresses on the tool and workpiece surface [12][13][14]. This results from the axial oscillation of the tool during the cutting process [11,[15][16][17]. In this paper, results of alloy modification of a NiCrSiFeB alloy and its influence on occurring cutting forces, temperatures, tool wear, and resulting surface roughness are presented. ...
The reduction of CO2 emissions is closely linked to the development of highly efficient and economical steel components in plant and process engineering. To withstand the high combined corrosive, tribological, thermal, and mechanical stresses, wear-resistant coatings tailored to the application and steel grade are used. In addition to the increasing demand to substitute conventional cobalt alloys with nickel alloys, there is also a growing need for defined or functional surfaces of high integrity. Due to high tool wear, milling operations required to produce the complex geometries of the components are often not economically feasible for SMEs. By means of alloy modification of the filler metals for nickel-based plasma build-up welded wear-resistant coatings and by the use of innovative ultrasonic-assisted milling processes more favourable machinability shall be achieved without reducing the wear protection potential. In this paper, the influence of the microstructure and precipitation morphology adjusted by means of alloy modification on the machinability is investigated. This is done based on a wear protection alloy NiCrMoSiFeB (trade name: Colmonoy 56 PTA) typically used for screw machines, which substitutes conventional CoCr alloys (Stellite). Metallurgical investigations and in-situ measurements of occurring process forces and temperatures at the tool cutting edge during milling as well as subsequent investigations of tool wear and surface integrity allow a detailed analysis and correlation between microstructural properties and machinability. For the cast samples, a clear change in the microstructure and hardness can be seen through the addition of Al, Ti, or Nb. These differences lead to an improvement in the machining process for Nb. Al and Ti cause long-needled or star-shaped precipitations and hardness increases, which lead to higher cutting forces and increased tool wear.
... For the attainment to reduce cutting time the frequency and amplitude of ultrasonic vibration should be enhanced or the spindle speed should be diminished [31]. By reducing the toolworkpiece engagement time, the machining force is also diminished. ...
... Vibration in 1D/2D is commonly induced directly on the workpiece via a vibrating machining bed [6]. LTVAM, on the other hand, is a relatively developing vibration method produced through the toolnot the workpieceand amplified via a component known as horn or sonotrode, which will be discussed further [7,8]. LTVAM movement is illustrated in Figure 1. ...
... On the other hand, when vibrations are induced, the generated toolpath will be influenced by the beat. Figure 3 shows the difference between the toolpath generated by conventional machining (standard curved path) and LTVAM (zig-zagged way, bold), which could be predicted by using these formulas [7] ( ) = + (2 60 + (2 : Phase Difference (degree) Figure 4. Comparison of conventional milling and LTVAM toolpath. ...
Micromachining is an advanced microfabrication technique for micro-sized or micro-accuracy products through subtractive manufacturing such as micro-milling. Vibration-assisted machining (VAM) is a method in which small amplitude vibrations are applied to the tool or workpiece to enhance the fabrication process. Milling results could be improved by adding longitudinal and torsional vibration to the tool using piezoelectric components vibrating at the ultrasonic frequency with an amplitude of less than 1 μm is used. A slip ring is required to transmit electric power from a static structure to a rotating frame. After the power has been transmitted to the system, an ultrasonic horn, called an acoustic horn or sonotrode, amplifies the vibrations at the tool’s tip. Since the excitation vibration is only longitudinal, the magnification of the vibration at the tooltip is also only longitudinal. Grooves are added to the side of the ultrasonic horn to produce torsional vibrations. This vibration is then simulated through finite element analysis software, explicitly using explicit dynamics. A 3D simulation is run for a quarter cycle of micro-milling through a Ti-6Al-4V material. It could be concluded that the LTVAM application may improve machining quality, such as temperature reduction of up to 9%, cutting force reduction of up to 35%, and surface roughness improvement of up to 27%.
... Another advantage, the LT-VAMILL method, can reduce the size of the burr, which has been proven by researchers; Wang et al. [9] stated that the burr on the outer side of the hole decreased by 45% from the average yield of the conventional method, Xu et al. [10] obtained a burr improvement result of 23% to 38%. Likewise, with the improvement of surface roughness as proven by the following researchers, Rinck et al. [11] stated that the surface roughness decreased from = 0.9 to 0.78 (L-VAM) and 0.75 (LT-VAMILL). Some evidence of the LT-VAMILL method's superiority above becomes the excellent reason for conducting a longitudinal-torsional VAM system study in its application to micro milling, considering aspects that should be involved in the design and analysis of micro milling. ...
... Table 1 provides an overview of the mathematical models that have been developed using UVAMM. 62 Percentage of the studies conducted on processing factors ...
... controlling the size and shape of chips, improving cutting efficiency and processing quality [8][9][10]. Compared with traditional cutting, vibration cutting has great potential in reducing cutting temperature, extending tool life, and improving machining quality [11][12][13]. ...
As a typical difficult-to-machine material which is widely used in aerospace and aviation field, the high quality and efficient machining of nickel-based alloys has always been the hotspot in mechanical machining. However, the problem of force and heat concentrations can reduce the machining stability of nickel-based alloys, leading to tool wear and work hardening, seriously affecting the flow direction and fracture of chips. Therefore, a novel low-frequency vibration-assisted turning device is developed by using adjustable dual eccentric mechanism in this paper. The chip separation conditions of low-frequency vibration turning is analyzed. The relationship between cutting parameters and cutting force, cutting temperature, tool wear, workpiece surface morphology, and tool life was studied through experiments. The experimental results demonstrate that the low-frequency vibration-assisted turning device can effectively suppress cutting force fluctuations, reduce cutting temperature, delay tool wear speed, improve surface quality, and increase tool life, meeting the high-quality and efficient machining requirements of nickel-based alloys. The research results will provide theoretical support for the problem of chip breakage in difficult to machine materials and the study of low-frequency vibration-assisted cutting technology.
... Consequently, the efficiency of machining technologies plays a significant role in the economical processing of high-performance materials. Conventional machining of these materials results in high cutting forces, increased tool wear, and a low material removal rate [1]. These disadvantages can be counteracted by ultrasonic vibration-assisted machining (UVAM) [2][3][4] and cryogenic minimum quantity lubrication (CMQL) [5][6][7][8]. ...
... In vibration-assisted machining, a high-frequency oscillation -often in the ultrasonic (US) range -with an amplitude of a few micrometers is superimposed on the machining process. The advantages of vibration-assisted machining are reduced cutting forces, an increased tool life, and an improved component quality [1,[9][10][11][12]. CMQL has become the focus of many investigations in recent years, which have demonstrated that adding oil to carbon dioxide (CO 2 ) cooling has an additional lubricating effect. ...
... Most investigations thus far have focused on turning because it is easier to apply a vibration superposition on a stationary tool than on a rotating one (e.g., milling). Rinck et al. [1], however, studied the influence of longitudinal vibration-assisted milling on machining of Ti-6Al-4V. Peripheral milling and slot milling were investigated. ...
Increasing demands on component properties are leading to the development of high-performance materials for which conventional production methods are reaching their limits from an economic and ecological point of view. In recent years, two technologies have been developed that show great potential compared to conventional machining processes, particularly in machining high-performance materials such as the titanium alloy Ti-6Al-4V. Ultrasonic-assisted machining leads to reduced cutting forces and increased tool life. Cryogenic minimum quantity lubrication prevents the occurrence of high machining temperatures and allows higher material removal rates without a negative impact on tool life. This paper shows the influence of ultrasonic-assisted milling and grinding processes in combination with cryogenic minimum quantity lubrication on the machinability of the high-strength materials Ti-6Al-4V and Zerodur. The investigation addressed cutting forces, tool wear, and surface roughness. The superposition of the technologies resulted in longer tool life and lower tool wear for both milling and grinding. However, the surface roughness was consistently higher due to the ultrasonic superposition. Nevertheless, machining with ultrasonic vibration-assisted cryogenic minimum quantity lubrication has great potential for difficult-to-machine materials, especially due to the reduction in tool wear.
... According to the experimental results, when A was 2 or 3 µm, the tool wear became stable as the cutting length increased. Figure 30(a) [176] shows that the helix angle, unit cutting-edge length, friction time, and cutting temperature increased. The influence of the helix angle on tool flank wear changed in a similar manner; that is, when the helix angle was 35°, the increase in the wear value was more stable than at other helix angles, as shown in Fig. 30(b) [176]. ...
... Figure 30(a) [176] shows that the helix angle, unit cutting-edge length, friction time, and cutting temperature increased. The influence of the helix angle on tool flank wear changed in a similar manner; that is, when the helix angle was 35°, the increase in the wear value was more stable than at other helix angles, as shown in Fig. 30(b) [176]. The errors between the predicted model and experimental results in the feed (x) and normal (y) directions of the coordinate tool system (o-xyz) were 19.1% and 12.9%, respectively. ...
... Compared to CM, the feed and normal cutting forces of UVAM decreased by 21.7% and 5.4%, respectively. When the cutting length exceeded 67.5 m, the tool wear value of UVAM decreased by 38.7% [176]. The application of twodimensional longitudinal torsional vibration can produce [174]. ...
Energy field-assisted machining technology has the potential to overcome the limitations of machining difficult-to-machine metal materials, such as poor machinability, low cutting efficiency, and high energy consumption. High-speed dry milling has emerged as a typical green processing technology due to its high processing efficiency and avoidance of cutting fluids. However, the lack of necessary cooling and lubrication in high-speed dry milling makes it difficult to meet the continuous milling requirements for difficult-to-machine metal materials. The introduction of advanced energy-field-assisted green processing technology can improve the machinability of such metallic materials and achieve efficient precision manufacturing, making it a focus of academic and industrial research. In this review, the characteristics and limitations of high-speed dry milling of difficult-to-machine metal materials, including titanium alloys, nickel-based alloys, and high-strength steel, are systematically explored. The laser energy field, ultrasonic energy field, and cryogenic minimum quantity lubrication energy fields are introduced. By analyzing the effects of changing the energy field and cutting parameters on tool wear, chip morphology, cutting force, temperature, and surface quality of the workpiece during milling, the superiority of energy-field-assisted milling of difficult-to-machine metal materials is demonstrated. Finally, the shortcomings and technical challenges of energy-field-assisted milling are summarized in detail, providing feasible ideas for realizing multi-energy field collaborative green machining of difficult-to-machine metal materials in the future.
