The International Journal of Advanced Manufacturing Technology | 2019
Finite element simulation and experimental investigation on cutting mechanism in vibration-assisted micro-milling
Abstract
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.