Dynamic surface generation modeling of two-dimensional vibration-assisted micro-end-milling

An integrated model is proposed to simulate the surface generation in two-dimensional vibration-assisted micro-end-milling (2-D VAMEM). The model includes the developed submodels as dynamic cutting force model, machining system response model, and machined surface generation algorithm. The effects of feed rate on cutting force and surface roughness are investigated through simulations. It is found that the cutting force increases while the surface roughness decreases with the increment of the feed rate when the feed per tooth is smaller than the tool edge radius. The trials have been carried out to evaluate and validate the proposed model and the simulation results. The integrated model contributes to the comprehensive understanding of the process of machined surface generation in 2-D VAMEM and will assist the machining operators to select optimal machining parameters.