Fundamental Aspects in Designing

Vibration Assisted Machining:

A Review
Presentation on

by:
G. Kiswanto and W. Libyawati
Department of Mechanical Engineering, Universitas Indonesia

Santika Premier, Malang, October 23rd-25th 2018

 Outline
1. Introduction
2. Why adding VAM to micro machining
3. Crucial aspect in adding VAM to micro machining
4. VAM benefit
5. Conclusion

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 Introduction
• Sustainable Machining
• Active and passive vibration
• Vibration Assisted Machining(VAM)
research development
Fig.1 Sustainable concept[1,2]

Fig.2 Vibration types in ultrasonic

precision machining[4]

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 VAM Researches Development

Fig.3 Tool tip trajectory without Fig.4 Barcode at TiAl6V4 [6]

Fig.5 Hybrid concept(hot
and with VAM additional[23]
treatment at workpiece and
Machining and vibration control VAM for turning process at the
parameter set up against machined VAM capability to make tool holder) [15]
surfaced quality[5-10,13] micro product[5-10, 13,14] Machining plot
• Thinner and discontinuous chip • Barcode • Assisted  to improve
formation • Micro dimple
machine capability [5-14]
• Separation period between tool- • Micro mold • Hybrid  combined
workpiece • Sculpture eyes contact
processes [15]
• Uniform cracking and MRR lens
• Ease to cut brittle material • Micro pore to mimicking
• Burr formation suppression living organism pore for
metal surface

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Why adding VAM to micro machining

Fig.6 Surface profile result without and with VAM[16]

Vibration mode Researchers Frequency Amplitude Achievement
(kHz) (μm)
1D VAM at Shen et 19.58 2-8 Surface roughness uniformity, force reduction
workpiece al.[19-21] during machining, thinner and discontinuous
chip formation
1D VAM at tool Denkena et 2;4 30 Ability to make barcode but not all surface is
holder al.[6] readable by the scanner
2D VAM at Ding et 1 2 Surface roughness reduction
workpiece al.[17]
Ding et 0.5-3 0.5-3 Flank wear reduction ranging between 5-20%
al.[22]
Jin & Xie[23] 5-11 1-4 Surface roughness reduction ranging between
38-40%
2D VAM at Chern & 0.6 10 Surface roughness reduction and increase the
worktable of Chang[24] dimension accuracy of the product
workpiece
2D VAM at tool Hui Ding et 1;3 2.5;7.5 Thinner and discontinuous chip formation
holder al.[25]
Kim & 18 0.5-2.2 Force reduction up to 50%
Loh[5]

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Fig.7 Cutting Method for VAM [12, 13, 16-18, 26]

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 Crucial Aspect in adding VAM
• Machine construction and system
Simulation and experimental study require to evaluate rigidity, mass, and
damping in order to obtain the natural frequency of the entire construction
• Actuator Selection
The assembly between actuator as part of VAM and the machine requires in
order uphold the static and dynamic load during machining.
• Types of VAM
The types influence the tool-workpiece separation pattern especially for VAM
placed at the workpiece.
• Types of material and product complexity
Different material has different machinability and require different parameter
set up during machining with VAM, that also applied for different product
complexity.

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 VAM BENEFIT
• Decrease machining forces
• Improve machined surface quality

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 Conclusion
• The relationship between machining parameter(feed
rate & depth of cut) and vibration control parameter
(frequency & amplitude) influenced the most
toward the machined surface quality
• Natural frequency and constraints from the existing
machine must be obtained before VAM placement
• 2D VAM Non-resonant at workpiece research is still
widely open and prospected to be developed

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THANK YOU

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