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Elliptical vibration assisted single point cutting (EVASPC) combines the kinematics of the ‘slow’ motion characteristic to conventional multi-axis CNC machines with that of the ‘ultrafast’ motion associated with ultrasonic elliptical vibrations. The summation of the slow and ultrafast motions results in a discontinuous contact between the cutting tool and the workpiece. This type of interrupted cut proved to be particularly advantageous in micro/nano fabrication of ferrous and other hard-to-cut materials. The primary objective of this study was to create a CAD/CAM framework capable to capture the aforementioned kinematic motions as well as predict the resulting surface. The developed framework was tested for a number of cutting strategies by means of analytical and geometric models that were subsequently validated by means of physical specimens replicating the targeted surface topography. The practical implementations of EVASPC demonstrated in this study include an optical surface quality surface (Sa < 14 nm), diffraction gratings, and saw-tooth microstructures, all with potential in various industrial applications.

CAD/CAM Framework for Generation of Surface Microstructures through Elliptical Vibration Assisted Single Point Cutting