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Finite element simulation and experimental analysis of axial ultrasonic vibration-assisted micro-milling of 316L stainless steel

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Abstract

Axial ultrasonic vibration-assisted micro-milling (UVAM) has emerged as an advanced technique that can be tailored to improve the machinability of difficult-to-machine materials such as 316L stainless steel. This article sets out to meticulously compare and analyze the cutting performance of conventional milling (CM) and UVAM techniques in the side milling of 316L stainless steel. The cutting separation characteristics of UVAM of 316L stainless steel are elucidated, and the air-cutting ratio in UVAM is introduced. The relationship between the air cutting ratio and spindle speed is also derived. Based on theory, the finite element simulation and experiments are compared under both milling conditions. An analysis of the results for these two sections is presented to validate the theoretical derivation. The results show that the trend and analysis of the experimental cutting forces are aligned with those in the simulation. The cutting forces also confirm the reliability of the simulation results. Due to factors such as tool wear, there is a deviation of 5–20% between the experimental values and the simulation results. A chip variation analysis in the simulation also corresponds to the trend in cutting temperature. An evaluation of the surface morphology and roughness of the experimental samples reveals that the surface quality and smoothness under UVAM are superior to those under CM. Tool wear analysis indicates that the carbide tool undergoes severe wear in the side milling of 316L stainless steel. In summary, the simulation and experiments convincingly demonstrate the advantages of UVAM technology and provide a reference for optimizing the milling process of challenging materials.

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Data availability

All data generated or analyzed during this study are included in this published article, and further request can be contacted with the corresponding author.

Abbreviations

CM:

Conventional milling

UVAM:

Axial ultrasonic vibration-assisted micro-milling

Z :

Number of tool teeth

I :

i Th tooth of the tool

R :

Tool radius

D :

Tool diameter

f z :

Feed per tooth

f u :

Feed rate

θ :

Angle that the tool has rotated

A :

Ultrasonic vibration amplitude

F :

Ultrasonic vibration frequency

n :

Spindle speed

a e :

Milling width

t :

Milling time

x i, y i, z i :

Cutting edge kinematic trajectory

k, k ' :

Slope

β :

Tool helix angle

β' :

Nominal helix angle

θ fl :

Dynamic rotation angle of the cutting edge

θ l :

Spindle rotation angle

ω fl :

Angular velocity of the cutting edge

ω l :

Angular velocity of the spindle

θ e :

Air cutting angle

θ c :

Cutting angle

δ :

Air cutting ratio

ρ :

Density

E :

Young’s modulus

ν :

Poisson ratio

γ :

Coefficient of thermal expansion

λ :

Thermal conductivity

C :

Specific heat capacity

A ', B, C ', n', m :

Johnson-Cook material constants

\(\varepsilon\) :

Equivalent plastic strain

\(\dot{\varepsilon }\) :

Equivalent plastic strain rate

\(\dot{{\varepsilon }_{0}}\) :

Reference strain

T melt :

Melting temperature

T room :

Room temperature

G :

Shear modulus

b :

Burgers vector

α :

Cutting front angle

μ :

Correction factor

L :

Length of the primary shear deformation zone

t min :

Minimum cutting thickness

t c :

Cutting layer thickness

t 0 :

Cutting thickness of chip formation

r e :

Cutting edge radius

γ 0 :

Tool rake angle

φ :

Shear angle

w :

Failure state scalar

\({\overline{\varepsilon }}_{0}^{pl}\) :

Initial equivalent plastic strain

\(\Delta {\overline{\varepsilon }}^{pl}\) :

Equivalent plastic strain increment

\({\overline{\varepsilon }}_{D}^{pl}\) :

Critical equivalent plastic strain

d 1, d 2, d 3, d 4, d 5 :

Failure parameters

p :

Material hydrostatic pressure

q :

Equivalent stress

\({\dot{\overline{\varepsilon }}}^{pl}\) :

Equivalent plastic strain rate

G f :

Fracture energy

K l :

Fracture toughness of the material

E ' :

Elastic modulus

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Funding

This work was supported by the Key Research and Development Plan in Shanxi Province of China (201803D421045).

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Authors and Affiliations

  1. College of Mechanical and Vehicle Engineering, Taiyuan University of Technology, Taiyuan, 030024, China

    Xu Feng, Zhiguo Dong, Bo Li & Hui Peng

  2. Shanxi Key Laboratory of Precision Machining, Taiyuan, 030024, China

    Xu Feng, Zhiguo Dong, Bo Li & Hui Peng

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Contributions

Xu Feng: methodology, investigation, data curation, formal analysis, writing—original draft, writing—review and editing. Zhiguo Dong: methodology, supervision, writing—review and editing. Bo Li: investigation, experimental support. Hui Peng: investigation, experimental support.

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Correspondence to Zhiguo Dong.

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Feng, X., Dong, Z., Li, B. et al. Finite element simulation and experimental analysis of axial ultrasonic vibration-assisted micro-milling of 316L stainless steel. Int J Adv Manuf Technol (2024). https://doi.org/10.1007/s00170-024-13807-1

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