Finite element simulation and experimental analysis of axial ultrasonic vibration-assisted micro-milling of 316L stainless steel

Axial ultrasonic vibration-assisted micro-milling (UVAM) has emerged as an advanced technique that can be tailored to improve the machinability of difficult-to-machine materials such as 316L stainless steel. This article sets out to meticulously compare and analyze the cutting performance of conventional milling (CM) and UVAM techniques in the side milling of 316L stainless steel. The cutting separation characteristics of UVAM of 316L stainless steel are elucidated, and the air-cutting ratio in UVAM is introduced. The relationship between the air cutting ratio and spindle speed is also derived. Based on theory, the finite element simulation and experiments are compared under both milling conditions. An analysis of the results for these two sections is presented to validate the theoretical derivation. The results show that the trend and analysis of the experimental cutting forces are aligned with those in the simulation. The cutting forces also confirm the reliability of the simulation results. Due to factors such as tool wear, there is a deviation of 5-20% between the experimental values and the simulation results. A chip variation analysis in the simulation also corresponds to the trend in cutting temperature. An evaluation of the surface morphology and roughness of the experimental samples reveals that the surface quality and smoothness under UVAM are superior to those under CM. Tool wear analysis indicates that the carbide tool undergoes severe wear in the side milling of 316L stainless steel. In summary, the simulation and experiments convincingly demonstrate the advantages of UVAM technology and provide a reference for optimizing the milling process of challenging materials.