Effect of tool wear in ultrasonic vibration-assisted micro-milling

Abstract

This article presents an experimental study on how tool wear affects tool life, surface roughness, and burr formation in ultrasonic vibration-assisted micro-milling. Small amplitude of vibration (2 µm) is applied to the micro-tools to evaluate the cutting performance influenced by tool flank wear as the cutting lengths increase. Compared to conventional milling, lower tool wear and better surface quality are recorded when cutting speed is much less than the maximum vibration speed. It is found that the use of minimum quantity lubrication in ultrasonic vibration-assisted micro-milling can further improve cutting performance due to reduction in tool wear.