Effect of process parameters on micro-textured surface generation in feed direction vibration assisted milling

Surface with certain macro/micro/nano structure has been earning more and more attentions owing to its good tribological behavior. However, some complex texture pattern is hard to fabricate, which hinders its wide application. In this study, feed direction ultrasonic vibration assisted milling (FDUAM), was proposed to realize the easy fabrication of micro-textured surface. Based on tool mapping principle, kinematic analysis was carried out aiming to explore the effect of main process parameters on tool trajectory, and also a surface topography simulation model was build. The numerical analysis results were validated by comparing results with experimental data. Three surface texture patterns, which are “micro-rib”, “micro-scale” and “micro-wave”, were realized at low spindle speed, medium spindle speed and high spindle speed, respectively. A preliminary friction test was at last conducted to investigate the tribological behaviors of various micro-textured surfaces. As results, it is found that the final surface topography is greatly influenced by the matching of vibrating parameters and milling parameters, two key parameters, i.e. η and λ, was supposed to be significant to the actual tool path and empty cutting time and finally the surface finishing. Friction test shows that although the fabricated micro-textures lead to the deterioration of surface roughness in most experimental cases, the three fabricated micro-textures studied in this case all make a great contribution to the improvement of surface friction property, particularly in term of load bearing capacity.