Modeling of static machining force in axial ultrasonic-vibration assisted milling considering acoustic softening
Modeling of static machining force in axial ultrasonic-vibration assisted milling considering acoustic softening
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DOI：
10.1016/j.ijmecsci.2017.11.048
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发表时间：
2018-02
影响因子：
7.3
通讯作者：
G. Verma;P. M. Pandey;U. S. Dixit
中科院分区：
文献类型：
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作者：
G. Verma;P. M. Pandey;U. S. Dixit
超声振动辅助铣削技术是铣削加工领域的最新进展之一。在轴向超声加工中，铣刀同时进行轴向高频小振幅的旋转和振动。实验研究表明，在铣削操作中叠加轴向超声振动通过降低切削力和提高表面光洁度来改善工艺。本研究主要针对立铣刀轴向振动的UAM加工过程进行解析研究。建立了轴向超声辅助铣削过程中切削力的过程物理模型。所建立的模型包括声软化、断续切削和立铣刀螺旋角效应。为了验证所开发的模型的实验装置开发。采用高速钢立铣刀对Al6063合金工件进行了轴向UAM加工。预测值和趋势与实验结果吻合良好。
Ultrasonic-vibration assisted milling (UAM) process is one of the most recent advancements in the area of milling. In axial UAM process, milling cutter is rotated and vibrated in axial direction simultaneously with high frequency and small amplitude. Experimental studies showed that superposition of axial ultrasonic vibrations in milling operation improved the process by reducing cutting forces and enhancing surface finish. This study is focused on analytical study of the UAM process with axial vibration of end milling tool. A process physics-based model was developed to evaluate the cutting forces in axial ultrasonic assisted milling process. The developed model included acoustic softening, intermittent cutting and end mill helix angle effects. For validation of the developed model an experimental setup was developed. Axial UAM of Al6063 alloy workpiece was carried out with a high speed steel end milling tool. The predicted values and trend were found in good agreement with experimental results.