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Experimental Investigations to Evaluate Machining Accuracy of Ultrasonic-Assisted Milling on Thin-Walled Structures

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Advances in Micro and Nano Manufacturing and Surface Engineering

Part of the book series: Lecture Notes on Multidisciplinary Industrial Engineering ((LNMUINEN))

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Abstract

Ultrasonic vibration-assisted milling (UAM) process is one of the most recent advancements in the area of milling. In axial UAM process, milling cutter is rotated and simultaneously vibrated in axial direction with high frequency and small amplitude. As observed experimentally, the superposition of axial ultrasonic vibrations in milling operation improved the performance of the process by reducing cutting forces and enhancing surface quality. This study intended to evaluate the machining accuracy of thin-walled structures milled with and without the assistance of ultrasonic vibration. Two different types of thin-walled (with straight and curved geometry) structures were machined by UAM and conventional milling to compare their machining accuracy. Accuracy of machined components was assessed following a reverse engineering technique. Experimental results indicated that the superposition of axial ultrasonic vibrations improved the machining accuracy of the typical milling process of up to 33%.

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Acknowledgements

Funding from the Engineering and Physical Sciences Research Council (UK) through grant EP/K028316/1 and Department of Science and Technology (India) through grant DST/RCUK/14-AM/2012 for project “Modeling of Advanced Materials for Simulation of Transformative Manufacturing Processes (MAST)” is gratefully acknowledged.

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Authors and Affiliations

  1. Department of Mechanical Engineering, Indian Institute of Technology Delhi, Delhi, 110016, India

    Girish Chandra Verma & Pulak Mohan Pandey

  2. Department of Mechanical Engineering, Indian Institute of Technology Guwahati, Assam, 781 039, India

    Uday Shanker Dixit

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  1. Girish Chandra Verma
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  2. Pulak Mohan Pandey
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  3. Uday Shanker Dixit
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Correspondence to Girish Chandra Verma .

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Editors and Affiliations

  1. Manufacturing Engineering Section, Department of Mechanical Engineering, Indian Institute of Technology Madras, Chennai, Tamil Nadu, India

    M. S. Shunmugam

  2. Department of Manufacturing Engineering, College of Engineering, Guindy, Anna University, Chennai, Tamil Nadu, India

    M. Kanthababu

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Verma, G.C., Pandey, P.M., Dixit, U.S. (2019). Experimental Investigations to Evaluate Machining Accuracy of Ultrasonic-Assisted Milling on Thin-Walled Structures. In: Shunmugam, M., Kanthababu, M. (eds) Advances in Micro and Nano Manufacturing and Surface Engineering. Lecture Notes on Multidisciplinary Industrial Engineering. Springer, Singapore. https://doi.org/10.1007/978-981-32-9425-7_12

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