Simulation and experiment of cutting force in ultrasonic torsional vibration assisted micro-milling

A coupled thermo-mechanical model of Ultrasonic Torsional Vibration Assisted Micro-milling (UTVAM) was established with ABAQUS, the primary cause which leads to a decrease in cutting force after adding Ultrasonic Torsional Vibration (UTV) to micro-milling was analyzed. Micro-milling with and without UTV were both carried out on the self-designed UTVAM experimental system, using forged aluminum alloy. Single-factor method was used to analyze the influence rules of cutting parameters such as spindle speed, feed per tooth and depth of cut on cutting force. It was found that feed per tooth plays a more important role than other parameters, a smaller feed per tooth can have a better effects on reducing of cutting force in UTVAM.