Chip Geometry Modelling of 2-Dimension Ultrasonic Vibration Assisted Machining (2D UVAM) on Micromilling Machine with End Mill

The needs of miniaturized products have increased a lot in this ever-changing world. This makes the micromanufacturing technologies develop fast in order to keep up with this higher needs and to meet the required quality of a product. One of the developed technologies is ultrasonic vibration assisted machining (UVAM). UVAM is different than conventional machining because of the way the cutting tool move relative to the workpiece. This different cutting phenomenon produces a different chip geometry than the conventional machining. The purpose of this paper is to give an understanding through chip geometry models about how UVAM can be a better cutting method rather than conventional milling. MATLAB is used in order to do the modelling of theoretical chip geometry. The approach used in this study is by calculating where the cutting tool edge is in a given unit of time before and after the ultrasonic vibration is induced to the workpiece in X-Y dimension. A characteristic in the cutting edge called the bottom cutting edge angle is also considered. By comparing the two chip geometries, some benefits that UVAM gives are explained.