Development of a Two-Dimensional Ultrasonic Device for Vibration-Assisted Milling

Two-dimensional vibration-assisted machining (VAM) is a technique used to improve the cutting performance of machining processes by reducing the cutting forces and the temperature, extending the tool life, and improving the surface quality. Among the developed 2D vibratory devices for VAM, some limitations affect the process stability. This paper aims to present a 2D vibratory device to be applied during the milling process with a setup structure overcoming the limitations of the other developed devices. The device operates at high vibration frequency, prevents the coupling effect problem, provides precise vibration motion, and is easily manufactured, assembled, installed, and maintained. Finite element analysis (FEA) was applied to verify and modify the proposed design. The components of the final design were manufactured, and the generated vibration in each direction was evaluated. A detailed control system was presented to maintain the stability for the applied vibration. Finally, slot-milling experiments were conducted to validate and test the device’s performance. The cutting experiments results showed some benefits of applying the ultrasonic vibration and validated that the 2D vibratory device is functioning properly