Modeling of static machining force in axial ultrasonic-vibration assisted milling considering acoustic softening

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. (C) 2017 Published by Elsevier Ltd.