Experimental study of biomedical stainless steel 316l vibration assisted milling using retrofittable 1D UVAM worktable

• Main Author: Abdul Latif, Abdul Afiff Fiqhry
• Format: Thesis
• Language: English; English; English
• Published: 2017
• Subjects: TJ1125-1345 Machine shops and machine shop practice
• Online Access: http://eprints.uthm.edu.my/732/1/24p%20ABDUL%20AFIFF%20FIQHRY%20ABDUL%20LATIF.pdf; http://eprints.uthm.edu.my/732/2/ABDUL%20AFIFF%20FIQHRY%20ABDUL%20LATIF%20COPYRIGHT%20DECLARATION.pdf; http://eprints.uthm.edu.my/732/3/ABDUL%20AFIFF%20FIQHRY%20ABDUL%20LATIF%20WATERMARK.pdf; http://eprints.uthm.edu.my/732/
• Institution: Universiti Tun Hussein Onn Malaysia

Nowadays, the demand in industry for hard and brittle materials including alloys and glasses components has been increasing. Thus, it is important to ensure machining for these parts are done in a high precision manner. Ultrasonic vibration assisted milling (UVAM) is a well-known precision machining equipment. It improves the machining performance and could perform machining on extremely delicate components. UVAM is an advance machining process which consists of the combination of conventional milling with ultrasonic vibration assistance. This research investigates the effect of imposing ultrasonic vibration assisted milling with feed and cross-feed vibration on conventional milling (CM). The desired vibration is proposed from the workpiece by a specialised one-dimensional UVAM worktable. A series of end-mill experiment in dry cutting conditions were conducted on stainless steel 316L. A commercially available cutting tool manufactured by HPMT with a diameter of 6 mm and featured with differential pitch was used in this research. The ultrasonic vibration generator excites the workpiece with a frequency in the range of 9~18 kHz and an amplitude of 0.5~3 μm. The values of the cutting parameter were chosen with regards to the recommendation by the manufacturers. Several parameters including cutting force, cutting temperature, surface roughness, chip formation and tool wear progression were compared between CM and UVAM. The results showed that a considerable improvement was identified in UVAM. It was found that end milling with ultrasonic vibration in the feed vibration of 18 kHz with an amplitude of 3 μm was able to reduce 13%(Fx) and 18%(Fy) of cutting force, reduce 18.4% of cutting temperature and improve the surface roughness up to 60% as compared to CM. Apart from that, it also decreased the tool wear progression as compared to conventional milling, In addition, the chip formation has shown a positive trend where larger amplitude and higher frequency would produce smaller chips as compared to conventional milling.