The Effect of Ultrasonic Vibrations on the Geometric Accuracy of the Work Piece in Aluminum 6061-T6 Milling

Achieving the required dimensional and geometrical accuracy as well as the appearance and performance quality in the production of industrial parts and the availability of interchangeability in the assembly and supply of spare parts for products has been one of the important challenges of the industry. In this research, the effect of adding axial ultrasonic vibration to the tool on the geometric accuracy of the Al6061-T6 work piece in the milling process was investigated. By analyzing the results, it was found that the presence of axial ultrasonic vibration improves the parallelism and flatness of the wall and the smoothness of the bottom surface as well as the perpendicularity of the wall with the bottom. It was also observed that a higher feed speed increases geometric deviations and surface roughness, while a higher cutting speed reduces them. By comparing the graphs, it was found that the positive effect of ultrasonic vibrations on the quality of the surface and the geometric accuracy of the work piece is more noticeable in the conditions of lower cutting speed and higher feed; That is, the condition in which we face the worst surface quality and the lowest geometric accuracy in conventional milling.