Study on Ultrasonic-Vibration Milling Process(1st Report): Investigation of Fundamental Cutting Performance and Application to Small-Diameter Ball-Nosed End Milling Process

In this study, the authors investigated to improve the cutting performance of the milling process using a small-diameter ball-nosed end mill. The problems associated with this milling process are as follows: First, the shape accuracy and surface integrity of products and the tool life can easily be rendered inferior because of the occurrence of bending or vibration of the end mill owing to low rigidity of the tool. Second, a high level of surface roughness of the surface cut by the center web of the and mill can easily occur, because the cutting capacity of this cutting edge is poor and the cutting speed is low. In an effort to solve these problems, the authors investigate a countermeasure in which ultrasonic vibration is applied during end milling process. As results, bending of the small-diameter end mill is prevented, the shape accuracy and surface integrity of products are improved, and also the tool life is lengthened by ultrasonic end milling in which the end mill is axially vibrated with ultrasonic frequency. Thus, it is believed that ultrasonic-vibration milling is effective in the improvement of the cutting performance of the milling process using the small-diameter ball-nosed end mill.