Simulation of Residual Stress in Ultrasonic Vibration Assisted Micro-Milling

Abstract

The machining-induced residual stresses are strongly dependent on the work-piece material and the chosen process parameters. A 2D finite element (FE) model of ultrasonic vibration assisted micro-milling (UVAMM) is established using ABAQUS. Johnson-Cook’s work-piece material and shear failure principle are used, while friction between tool and work-piece uses modified Coulomb’s law whose sliding friction area is combined with sticking friction. By means of FE analysis, the influence rules of spindle speed, vibration frequency and work-piece material on the surface residual stresses are obtained, which provides a basis for choosing optimal process parameters and improving the longevity and reliability of micro-component.