Finite element simulation investigation on ultrasonic vibration assisted micro milling of AISI 410 grade MSS

The exceptional physical and mechanical properties of AISI 410 martensitic stainless steel (MSS) have made it a popular choice in the automotive and aviation industries. However, it is also a typically difficult-to-cut material due to its elevated hardness and brittleness. To address the problems of high cutting forces and poor surface quality in conventional micro milling (CMM), ultrasonic vibration-assisted micro milling (UVAMM) has been proposed that can effectively reduce the cutting forces and improve the surface quality of the material. In this study, to thoroughly investigate the characteristics of UVAMM, a 3D finite element cutting model was developed using Deform 3D simulation software. A comprehensive investigation was carried out to compare the cutting forces, cutting temperature, tool wear, burr formation, and other variables between CMM and UVAMM. The findings demonstrate that applying high-frequency ultrasonic vibration along the milling feed direction effectively enhances chip breaking ability and achieves a reduction in burr formation, cutting forces, cutting temperature, and tool wear. In addition, ultrasonic amplitude also has a significant impact on improving cutting efficiency. The results show that in UVAMM, when the amplitude increases from 1 μm to 3 μm, it further reduces burr formation, cutting forces, cutting temperature, and tool wear, thus improving the surface finish quality.