Chatter marks reduction in meso-scale milling through ultrasonic vibration assistance parallel to tooling’s axis

Recently, vibration assistance has been mainly applied to feed and cross-feed directions for milling processes. This paper investigates the effect of ultrasonic vibration assistance in tooling’s axial direction for improvement of machined surface with reduction of chatter marks. With the designed ultrasonic vibration assisted milling process with 39.7 kHz and a few micro-meter amplitudes, workpiece vibrates along tooling’s axial direction while various cutting speeds and feed rates are applied. In addition to a cutter rotation motion, the axial directional vibration assistance acts as additional cutting motion which further reduces the leftover surface error. Experimental results validate that surface roughness can be improved with the reduced chatter marks through the axial directional vibration assistance for the tested conditions. Finally, process simulation demonstrates that milling stability can be enhanced with the tooling’s ultrasonic vibration assistance, which explains the experimental phenomenon of the chatter marks reduction of the mesoscale milling processes.

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