Investigation of the effect of cutting speed and vibration amplitude on cutting forces in ultrasonic-assisted milling

In this article, critical cutting speed in ultrasonic-assisted milling has been calculated and tool–workpiece separation zones have been determined analytically. In order to investigate the ultrasonic-assisted milling process, a special experimental setup has been designed and established that applies one dimensional vibration to the workpiece. Cutting forces in conventional milling and ultrasonic-assisted milling processes have been measured experimentally and the effect of cutting speed and workpiece vibration amplitude on cutting forces have been investigated. As cutting speed increases, the degree of tool–workpiece engagement in one tool revolution increases; as a result, the effect of ultrasonic vibration on milling process decreases and cutting forces in ultrasonic-assisted milling and conventional milling processes become closer to each other. An increase in vibration amplitude increases the reduction rate of cutting forces in the ultrasonic-assisted milling process compared with conventional milling process.