Theoretical and experimental research on the features of cutting force in rotary ultrasonic face milling of K9 glass

This study introduces rotary ultrasonic face milling (RUFM) process into flat surface machining of K9 glass. The effective cutting velocity, and cutting length of single diamond particle were presented in RUFM. The model of material removal for RUFM was developed through examining indentation fracture mechanics theory and material removal characteristics of brittle materials, and analyzing kinematics properties of diamond grits in RUFM. With a view of comparative researches, the cutting force of RUFM and diamond milling of K9 glass are compared. The experimental results tell that the relationship between the cutting depth (d(c)) and the ultrasonic amplitude (A) of the cutter has remarkable effects on cutting force, which was also discussed in the kinematic characteristics analysis section. The results also show that RUFM process can significantly reduce cutting force and the effects of process variable changes on cutting force in RUFM are weaker as d(c) is smaller than A. However, the reduction trends of the cutting forces in RUFM are very small and even increased in some process conditions, as d(c) is larger than A. It suggests that the cutting depth should be smaller than the ultrasonic amplitude of the cutter with RUFM process to obtain better processing performance.