Generation mechanism of surface micro-texture in axial ultrasonic vibration-assisted milling (AUVAM)

Although axial ultrasonic vibration-assisted milling (AUVAM) is promising for rapid and economical fabrication of 3D micro-texture on various surfaces, it has been a challenge to obtain with small feature size large height simultaneously. The mechanism major influence factors the formation by this method were explored in study. It was found that generation mainly caused cutting extrusion from flank face tool under vibration. Therefore, novel model considered relief angle, end edge angle blade profile established simulation analysis. good agreement between experimental results demonstrated attributed tool. first time report both shape unit affected overlap surface micro-texture. But diminished increase spindle speed. sinusoid-shaped minimum width 20 μm 2 (fully reproduced amplitude) realized 40° speed 4000 rpm. Other typical textures weave, shell, scale corrugation also presented show effective regulation texture patterns AUVAM. This work provides theoretical practical basis such low-cost, efficient controllable preparation method.