Theoretical and Experimental Investigation of Surface Textures in Vibration-Assisted Micro Milling

Vibration-assisted micro milling is a promising technique for fabricating engineered mi-cro-scaled surface textures. This paper presents a novel approach for theoretical modeling of three-dimensional (3D) surface textures produced by vibration-assisted micro milling. The proposed model considers the...

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Published inMicromachines (Basel) Vol. 15; no. 1; p. 139
Main Authors Song, Bowen, Zhang, Dawei, Jing, Xiubing, Ren, Yingying, Chen, Yun, Li, Huaizhong
Format Journal Article
LanguageEnglish
Published Switzerland MDPI AG 01.01.2024
MDPI
Subjects
Animal behavior
Control surfaces
Costs (Law)
Degrees of freedom
Elastic recovery
Feed direction
Geometry
Heat treating
Machining
Mathematical models
micro milling
Milling (machining)
Process parameters
Surface layers
surface texture machining
Texturing
Three dimensional models
Titanium alloys
Vibration
vibration-assisted machining
micro milling
surface texture machining
vibration-assisted machining
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Summary:Vibration-assisted micro milling is a promising technique for fabricating engineered mi-cro-scaled surface textures. This paper presents a novel approach for theoretical modeling of three-dimensional (3D) surface textures produced by vibration-assisted micro milling. The proposed model considers the effects of tool edge geometry, minimum uncut chip thickness (MUCT), and material elastic recovery. The surface texture formation under different machining parameters is simulated and analyzed through mathematical modeling. Two typical surface morphologies can be generated: wave-type and fish scale-type textures, depending on the phase difference between tool paths. A 2-degrees-of-freedom (2-DOF) vibration stage is also developed to provide vibration along the feed and cross-feed directions during micro-milling process. Micro-milling experiments on copper were carried out to verify the ability to fabricate controlled surface textures using the vibration stage. The simulated and experimentally generated surfaces show good agreement in geometry and dimensions. This work provides an accurate analytical model for vibration-assisted micro-milling surface generation and demonstrates its feasibility for efficient, flexible texturing.
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ISSN:2072-666X
2072-666X
DOI:10.3390/mi15010139