Surface analysis in rotary ultrasonic-assisted milling of CFRP and titanium

Nowadays, tools with the ability to machine advanced materials is very much needed by industries. Therefore, design and manufacture of a rotary ultrasonic assisted machining tool is carried out in this study. In order to evaluate this tool, the milling process is conducted on the carbon fiber reinforced polymer composite and titanium materials where cutting forces, surface roughness, and fiber pull-out are selected as key factors for analysis. As a result, it is seen that the manufactured tool has a good performance in milling of advanced material. In particular, it is shown that fiber pull-out is eliminated when the ultrasonic tool is used in milling of CFRP. In addition, surface roughness is reduced about 15 %. Meanwhile, micro-texture can be generated on the surface of titanium workpiece by using harmonic movement of end mill.