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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. [ABSTRACT FROM AUTHOR]

Edge-chipping, surface roughness and dimensional accuracy are crucial quality aspects of drilled holes in hard-to-cut material such as glass, ceramics and carbon fiber reinforced plastics. In this article, an experimental study was conducted to investigate the quality measures of holes produced by rotary ultrasonic drilling (RUD) and conventional drilling. Edge-chipping width at tool exit side, the surface roughness (Ra and Rz), out-of-roundness, cylindricity error and hole conicity were the main responses when drilling soda glass using diamond abrasive tools and a cutting fluid. Statistically designed experiments were carried out for rotary ultrasonic and conventional drilling (CD) at two levels of tool feed rate (0.6 and 6 mm/min), spindle speed (3,000 and 8,000 rpm) and tool particles-concentration. Analysis of variance was used to define the significant factors and their interactions and build models for predicting the responses. The results showed that reducing the chipping, surface roughness and roundness error. The normal tool concentration showed a substantial effect in improving the surface quality and reducing the hole-geometrical errors. [ABSTRACT FROM AUTHOR]

Soda glass is a difficult-to-machine material widely used in industry. In this work, ultrasonic-assisted milling (UAM) of soda glass is investigated and compared to conventional milling (CM). Statistically designed experiments are conducted with and without cutting fluid at different levels of the spindle speed, feedrate, depth of cut, and tool particle-concentration. The significant factors and their interactions are identified by modelling the process parameters and the corresponding responses in terms of cutting forces and moment. Results show a reduction of axial cutting force and moment at higher spindle speed and lower feedrate and depth of cut. The application of ultrasonic vibration-assistance and cutting fluid demonstrates a significant effect on the axial cutting force and moment. [ABSTRACT FROM AUTHOR]