Improving Slot Milling Performance Using Ultrasonic Assisted Vibration

El-Gouhary, Mahmoud Reda; Nassef, Ahmed; Othman, Gamal Abdel Nasser; Baraya, Mohamed

doi:10.21608/pserj.2024.307397.1355

Improving Slot Milling Performance Using Ultrasonic Assisted Vibration

Document Type : Original Article

Authors

¹ Production Engineering and Mechanical Design Department, Faculty of Engineering, Port Said University, Port Said, Egypt

² Department of Production and Mechanical Design Engineering, Faculty of Engineering, Port-Said University, Port-Fouad, Port-Said 42523, Egypt

³ Department of Production Engineering and Mechanical Design, Faculty of Engineering, Port Said University, Port Said 42526, Egypt

10.21608/pserj.2024.307397.1355

Abstract

Conventional machining methods face significant challenges when working with hard-to-cut materials, such as advanced ceramics, high-strength alloys, and composites. These challenges include poor surface quality, rapid tool wear, and high cutting forces. This study investigates the enhancement of machining performance through the application of Vibration-Assisted Machining (VAM). By introducing controlled high-frequency vibrations (typically around 26 kHz) to the workpiece side, UVAM aims to improve machinability parameters.

The research explores the principles behind UVAM and its impact on reducing cutting forces, improving surface finish, and enhancing debris evacuation. The potential benefits of UVAM, such as improved surface integrity and reduced cutting forces, are discussed. Experimental results demonstrate a significant reduction in cutting forces, surface roughness, and cutting temperature, as well as an extension of tool life. These improvements highlight the efficacy of VAM in machining hard-to-cut materials.

The study concludes that VAM has the potential to revolutionize the machining process, making it more efficient and precise. Further research is recommended to fully understand the underlying mechanisms and optimize VAM parameters for various materials and machining processes. This will pave the way for broader adoption of VAM in industrial applications.

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