Theoretical Modeling and Surface Roughness Prediction of Microtextured Surfaces in Ultrasonic Vibration-Assisted Milling  

作　　者：Chenbing Ni Junjie Zhu Youqiang Wang Dejian Liu Xuezhao Wang Lida Zhu 

机构地区：[1]School of Mechanical and Automotive Engineering,Qingdao University of Technology,Qingdao 266525,China [2]School of Mechanical Engineering and Automation,Northeastern University,Shenyang 110819,China

出　　处：《Chinese Journal of Mechanical Engineering》2024年第2期163-183,共21页中国机械工程学报（英文版）

基　　金：Supported by Shandong Provincial Natural Science Foundation of China(Grant No.ZR2023QE041);China Postdoctoral Science Foundation(Grant No.2023M731862);National Natural Science Foundation of China(Grant No.51975112).

摘　　要：Textured surfaces with certain micro/nano structures have been proven to possess some advanced functions,such as reducing friction,improving wear and increasing wettability.Accurate prediction of micro/nano surface textures is of great significance for the design,fabrication and application of functional textured surfaces.In this paper,based on the kinematic analysis of cutter teeth,the discretization of ultrasonic machining process,transformation method of coordinate systems and the cubic spline data interpolation,an integrated theoretical model was established to characterize the distribution and geometric features of micro textures on the surfaces machined by different types of ultrasonic vibration-assisted milling(UVAM).Based on the theoretical model,the effect of key process parameters(vibration directions,vibration dimensions,cutting parameters and vibration parameters)on tool trajectories and microtextured surface morphology in UVAM is investigated.Besides,the effect of phase difference on the elliptical shape in 2D/3D ultrasonic elliptical vibration-assisted milling(UEVAM)was analyzed.Compared to conventional numerical models,the method of the cubic spline data interpolation is applied to the simulation of microtextured surface morphology in UVAM,which is more suitable for characterizing the morphological features of microtextured surfaces than traditional methods due to the presence of numerous micro textures.The prediction of surface roughness indicates that the magnitude of ultrasonic amplitude in z-direction should be strictly limited in 1D rotary UVAM,2D and 3D UEVAM due to the unfavorable effect of axial ultrasonic vibration on the surface quality.This study can provide theoretical guidance for the design and fabrication of microtextured surfaces in UVAM.

关 键 词：Theoretical modeling Microtextured surface Ultrasonic vibration-assisted milling Cubic spline interpolation Surface roughness 

分 类 号：TG146.23[一般工业技术—材料科学与工程]