Finite element simulation and experimental investigation on cutting mechanism in vibration-assisted micro-milling

In vibration-assisted milling, vibrations are applied in feed and/or cross-feed directions during micro-milling process, and instantaneous cutting thickness can be changed significantly. As a result, its cutting mechanics also change dramatically. This paper investigates the underlying cutting mecha...

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Bibliographic Details
Published in:International journal of advanced manufacturing technology 2019-12, Vol.105 (11), p.4539-4549
Main Authors: Chen, Wanqun, Zheng, Lu, Teng, Xiangyu, Yang, Kai, Huo, Dehong
Format: Article
Language:English
Subjects:
CAE) and Design
Computer simulation
Computer-Aided Engineering (CAD
Cutting force
Cutting parameters
Cutting wear
Engineering
Feed direction
Finite element method
Industrial and Production Engineering
Magnesium base alloys
Mathematical models
Mechanical Engineering
Media Management
Milling (machining)
Milling industry
Original Article
Simulation
Size effects
Tool wear
Vibration
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Summary:In vibration-assisted milling, vibrations are applied in feed and/or cross-feed directions during micro-milling process, and instantaneous cutting thickness can be changed significantly. As a result, its cutting mechanics also change dramatically. This paper investigates the underlying cutting mechanism of vibration-assisted micro-milling by using finite element (FE) simulations and experiments. A finite element model of vibration-assisted micro-milling process is established for magnesium alloys machining with the Johnson-Cook material model. The vibration-assisted micro-milling is investigated in terms of size effect and material removal mechanism. It is found that vibration frequency has a significant influence on the machining mechanism, e.g. suppression of burr formation and reduction of cutting forces and tool wear. The FE simulation results are compared with the conventional micro-milling and verified by the experimental results.
ISSN:0268-3768
1433-3015
DOI:10.1007/s00170-019-03402-0