Rotary Ultrasonic Machining (RUM) stands as a crucial method for machining hard and brittle materials. However, for machining hard-to-machine metal, it continues to face many challenges due to the complex vibration of the milling tool. Flank milling is an efficient method for machining complex parts, such as blisks and impellers, which have been widely used in aerospace field. However, current research is more focused on rotary ultrasonic end milling. In this context, we will study the surface integrity of rotary ultrasonic flank milling 40Cr steel using a self-developed RUM system. We delve into exploring the impacts of tool vibration on surface morphology, residual stress, and micro-hardness of the workpiece under various process parameters. The experimental findings reveal that rotary ultrasonic flank milling, in contrast to traditional flank milling techniques, significantly diminishes the surface roughness by about 40%. The reasons for the reduction of surface roughness are analyzed from the point of view of the cutting force. The surface roughness appears to be notably linked to both the average cutting force and the frequency domain characteristics. In addition, the experimental results indicate that rotary ultrasonic flank milling demonstrates the capacity to elevate the micro-hardness of the machined surface.
Keywords: cutting mechanism; milling; rotary ultrasonic machining; surface quality.