Design and analysis of a desktop micro-machine for vibration-assisted micromachining

Machine design technology has changed rapidly in the past two decades in response to ever more demanding machining requirements. The aim of the research reported in this paper is to design and develop a desktop micro-machine for vibration-assisted machining. Using analytical and experimental results, updated finite element analysis (FEA) models are used to predict the effect of dynamic modifications in the structure of the machine that is to be used for vibration-assisted machining. Two sets of experiments are performed: modal testing using an impact hammer and analytical FEA modelling of the machine. This paper first outlines design analysis, configuration, conceptual design, dynamic analysis, and cutting trials, followed by the development of a two-dimensional vibration test bed, performance evaluation of its process, and characterization of dynamic behaviour using FEA. Then, it discusses the use of a piezo-actuator-based module to generate vibrations during machining operations. Finally, the result of dynamic analyses and machining trials are discussed.