Analytical and Numerical Investigation of Machining Forces of Ultrasonic Assisted Milling

Nowadays, with the advancement of materials science and the production of materials with special properties such as super alloys, composites and ceramics used in advanced industries, the use of traditional machining methods for the production of these parts is not possible. Therefore, the use of modern methods has been considered. One of these methods, which has the ability to add to traditional cutting processes, is the use of ultrasonic vibrations during the machining process. In this paper, analytical relations have been derived to calculate machining forces associated with ultrasonic vibration based on the undeformed chip thickness. Then numerical simulation of ultrasonic assisted milling process is performed by applying the vibrations to the workpiece in the feed direction by using the ABAQUS finite element software and the machining forces are determined. The results obtained by analytical and numerical data show that the use of ultrasonic vibrations can change the direction of movement of the tool and change the thickness of the undeformed chip and thus reduce the machining forces in the milling process. Also, based on the results, it was found that there is a good agreement between the results obtained from analytical analysis and 3D FEM modeling in macro scale.