Review of vibration-assisted machining

Vibration-assisted machining (VAM) combines precision machining with small-amplitude tool vibration to improve the fabrication process. It has been applied to a number of processes from turning to drilling to grinding [9,36]. The emphasis on this literature review is the turning process where VAM has been applied to difficult applications such as diamond turning of ferrous and brittle materials, creating microstructures with complex geometries for products like molds and optical elements, or economically producing precision macro-scale components in hard alloys such as Inconel or titanium. This review paper presents the basic kinematic relationships for 1 D (linear vibratory tool path) and 2D VAM (circular/elliptical tool path). Typical hardware systems used to achieve these vibratory motions are described. The periodic separation between the tool rake face and uncut material, characteristic of VAM, is related to observed reductions in machining forces and chip thickness, with distinct explanations offered for 1D and 2D modes. The reduced tool forces in turn are related to improvements in surface finish and extended tool life. Additional consideration is given to the intermittent cutting mechanism and how it reduces the effect of thereto-chemical mechanisms believed responsible for rapid wear of diamond tools when machining ferrous materials. The ability of VAM to machine brittle materials in the ductile regime at increased depth of cut is also described. (c) 2007 Elsevier Inc. All rights reserved.