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Simulation and Application of a Piezo-Driven System Enabling Vibration-Assisted Micro Milling

Authors Sebastian Greco, Katja Klauer, Benjamin Kirsch, Jan C. Aurich

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Author Details

Sebastian Greco
  • Institute for Manufacturing Technology and Production Systems, Technische Universität Kaiserslautern, Germany
Katja Klauer
  • Institute for Manufacturing Technology and Production Systems, Technische Universität Kaiserslautern, Germany
Benjamin Kirsch
  • Institute for Manufacturing Technology and Production Systems, Technische Universität Kaiserslautern, Germany
Jan C. Aurich
  • Institute for Manufacturing Technology and Production Systems, Technische Universität Kaiserslautern, Germany

Funding

The authors would like to thank the German research foundation (DFG) for the financial support within the project AU 185/57-1 "Ultrasonic air bearing spindle for micro machining". Also funded by the Deutsche Forschungsgemeinschaft (DFG, German Research Foundation) - project number 172116086 - SFB 926.

Cite As Get BibTex

Sebastian Greco, Katja Klauer, Benjamin Kirsch, and Jan C. Aurich. Simulation and Application of a Piezo-Driven System Enabling Vibration-Assisted Micro Milling. In 2nd International Conference of the DFG International Research Training Group 2057 – Physical Modeling for Virtual Manufacturing (iPMVM 2020). Open Access Series in Informatics (OASIcs), Volume 89, pp. 3:1-3:18, Schloss Dagstuhl – Leibniz-Zentrum für Informatik (2021) https://doi.org/10.4230/OASIcs.iPMVM.2020.3

Abstract

The ongoing miniaturization of components and the functionalization of surfaces necessitates the improvement of micro machining processes and to increase their efficiency. One method to increase the machining efficiency is reducing the process forces and tool wear, which is achieved by the implementation of vibration-assisted cutting in conventional machining processes. In vibration-assisted cutting, the conventional cutting movement is superimposed by a vibration with defined frequency. By using vibration-assisted cutting technologies, besides increased efficiency, a wider range of materials can be machined. In this paper, vibration-assisted cutting is transferred to micro machining. For this purpose, the design, simulation and application of an easy to integrate system that enables vibration-assisted cutting for micro machining processes is described. The setup was tested using a micro milling process. Two orientations between feed direction and vibration direction were investigated. Frequencies up to 15 kHz were examined, the machined material was brass (CuZn39Pb2). The effect of the superimposed vibration was analysed on the basis of process force, surface roughness, burr formation and slot bottom and was compared with the process results of micro milling without vibration-assistance. A decrease in process forces of up to 63 % was observed during vibration-assisted micro milling.

Subject Classification

ACM Subject Classification
  • Applied computing → Physical sciences and engineering
Keywords
  • micro machining
  • micro milling
  • vibration-assisted cutting
  • Finite Element Analysis
  • surface roughness

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