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Finite element simulation and experimental investigation on cutting mechanism in vibration-assisted micro-milling

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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.

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Funding

This work was financially supported by the National Natural Science Foundation of China (Grant No.51505107), the National Science and Technology Program (2015DFA70630) and the Engineering and Physical Sciences Research Council (EP/M020657/1).

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Authors and Affiliations

  1. School of Engineering, Newcastle University, Newcastle upon Tyne, NE1 7RU, UK

    Wanqun Chen, Lu Zheng, Xiangyu Teng & Dehong Huo

  2. School of Mechatronics Engineering, Harbin Institute of Technology, Harbin, 150001, People’s Republic of China

    Wanqun Chen

  3. Army Aviation Institute, Beijing, 101123, People’s Republic of China

    Kai Yang

Authors
  1. Wanqun Chen
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  2. Lu Zheng
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  3. Xiangyu Teng
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  4. Kai Yang
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  5. Dehong Huo
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Correspondence to Dehong Huo.

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Chen, W., Zheng, L., Teng, X. et al. Finite element simulation and experimental investigation on cutting mechanism in vibration-assisted micro-milling. Int J Adv Manuf Technol 105, 4539–4549 (2019). https://doi.org/10.1007/s00170-019-03402-0

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  • DOI: https://doi.org/10.1007/s00170-019-03402-0

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