A novel finite element simulation approach for analyzing distortion and residual stress in ultrasonic-assisted milling

A novel finite element simulation approach for analyzing distortion and residual stress in ultrasonic-assisted milling | Research Square window.SnipcartSettings = { analytics: { enabled: false } }; (function() { var accessVector = localStorage.getItem('access_vector') || ''; window.dataLayer = window.dataLayer || []; if (accessVector) { window.dataLayer.push({ user: { profile: { profileInfo: { snid: accessVector } } } }); } })(); (function(w,d,s,l,i){w[l]=w[l]||[];w[l].push({'gtm.start':new Date().getTime(),event:'gtm.js'});var f=d.getElementsByTagName(s)[0],j=d.createElement(s),dl=l!='dataLayer'?'&l='+l:'';j.async=true;j.src='https://www.googletagmanager.com/gtm.js?id='+i+dl;f.parentNode.insertBefore(j,f);})(window,document,'script','dataLayer','GTM-K279D39R'); Browse Preprints In Review Journals COVID-19 Preprints AJE Video Bytes Research Tools Research Promotion AJE Professional Editing AJE Rubriq About Preprint Platform In Review Editorial Policies Our Team Advisory Board Help Center Sign In Submit a Preprint Cite Share Download PDF Research Article A novel finite element simulation approach for analyzing distortion and residual stress in ultrasonic-assisted milling masuod bayat, Saeid Amini This is a preprint; it has not been peer reviewed by a journal. https://doi.org/ 10.21203/rs.3.rs-6486120/v1 This work is licensed under a CC BY 4.0 License Status: Posted Version 1 posted You are reading this latest preprint version Abstract The cutting forces, residual stresses, and workpiece distortion in machining processes largely influence the quality of the end product. An advanced technique for the amelioration of these parameters is ultrasonic-assisted milling (UAM), which induces high-frequency vibrations onto the cutting tool to intermittently disrupt tool-workpiece contact, aiding in the removal of material more effectively. This study focuses on ultrasonic-assisted milling and its effects on cutting forces, workpiece distortion, tensile residual stress, and surface integrity via finite element simulation and experimental approaches. A numerical model was built in ABAQUS first and validated against experimental observations. In the experiments, aluminum 7075 was selected as the workpiece material, and various machining parameters including spindle speed, feed rate, and milling method were investigated. The results indicated that UAM reduced cutting forces up to 25%, workpiece distortion of 21.5%, and tensile residual stresses by 23% compared to conventional milling (CM). Microscopic investigations revealed better surface integrity in the UAM compared to CM, as trace scratches were less and there were fewer surface defects. The comparison between simulations and experimental findings also yielded good correlation with a deviation in output parameters within 11%. This finding demonstrates that ultrasonic-assisted milling is an effective method for improving dimensional accuracy and surface quality in the machining process. Ultrasonic-Assisted Milling (UAM) Conventional Milling (CM) Cutting Force Residual Stress Distortion Surface Integrity Finite Element Simulation Experimental Analysis Aluminum 7075 Full Text Supplementary Files Highlight.docx Cite Share Download PDF Status: Posted Version 1 posted You are reading this latest preprint version Research Square lets you share your work early, gain feedback from the community, and start making changes to your manuscript prior to peer review in a journal. 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Also discoverable on Platform About Our Team In Review Editorial Policies Advisory Board Help Center Resources Author Services Accessibility API Access RSS feed Manage Cookie Preferences © Research Square 2026 | ISSN 2693-5015 (online) Privacy Policy Terms of Service Do Not Sell My Personal Information {"props":{"pageProps":{"initialData":{"identity":"rs-6486120","acceptedTermsAndConditions":true,"allowDirectSubmit":true,"archivedVersions":[],"articleType":"Research Article","associatedPublications":[],"authors":[{"id":450681122,"identity":"a0671ead-1ad5-4163-816b-974f85cf7c64","order_by":0,"name":"masuod bayat","email":"data:image/png;base64,iVBORw0KGgoAAAANSUhEUgAAAZAAAAAyAQMAAABI0h/eAAAABlBMVEX///8AAABVwtN+AAAACXBIWXMAAA7EAAAOxAGVKw4bAAAA1UlEQVRIiWNgGAWjYNACtn9y/OwNQIaBBdFaDhhL9hwAaZEgXkvihhsJIBYRWnTbjz+T+FB2h7Hh5vOrG34USDDwt3cn4NVidibHTHLGuWfMjLNzym72AB0mcebsBvxaDuSwSfO2MbMxS+ek3eABajGQyCWg5fzzZyAtPGySZ9Ju/iFKy40EM6CWwxI8EuzHbhNny403xpYzzqUZSPDksN2WAVKE/XI+/eGND2U29fuPH392880fGzn+9l78WpAAjwGYJFY5CLA/IEX1KBgFo2AUjCAAANyISPab9gDiAAAAAElFTkSuQmCC","orcid":"https://orcid.org/0000-0003-4454-9073","institution":"University of Kashan","correspondingAuthor":true,"prefix":"","firstName":"masuod","middleName":"","lastName":"bayat","suffix":""},{"id":450681123,"identity":"fac946d7-b73f-469a-888b-6accbf0de8ea","order_by":1,"name":"Saeid Amini","email":"","orcid":"","institution":"","correspondingAuthor":false,"prefix":"","firstName":"Saeid","middleName":"","lastName":"Amini","suffix":""}],"badges":[],"createdAt":"2025-04-19 17:44:16","currentVersionCode":1,"declarations":"","doi":"10.21203/rs.3.rs-6486120/v1","doiUrl":"https://doi.org/10.21203/rs.3.rs-6486120/v1","draftVersion":[],"editorialEvents":[],"editorialNote":"","failedWorkflow":false,"files":[{"id":84973007,"identity":"7ff68e58-7497-423a-91d4-c128d591b51c","added_by":"auto","created_at":"2025-06-19 11:32:16","extension":"pdf","order_by":1,"title":"","display":"","copyAsset":false,"role":"manuscript-pdf","size":2305360,"visible":true,"origin":"","legend":"","description":"","filename":"evejajpeledar.pdf","url":"https://assets-eu.researchsquare.com/files/rs-6486120/v1_covered_e8439023-de6d-4454-86c0-a6b633d87597.pdf"},{"id":82099842,"identity":"5ccb2fe1-a373-4b6d-af4c-d3e1c0b55d19","added_by":"auto","created_at":"2025-05-06 18:25:32","extension":"docx","order_by":4,"title":"","display":"","copyAsset":false,"role":"supplement","size":13390,"visible":true,"origin":"","legend":"","description":"","filename":"Highlight.docx","url":"https://assets-eu.researchsquare.com/files/rs-6486120/v1/1a8d4ae147ddd8d6a18e3fb6.docx"}],"financialInterests":"","formattedTitle":"A novel finite element simulation approach for analyzing distortion and residual stress in ultrasonic-assisted milling","fulltext":[],"fulltextSource":"","fullText":"","funders":[],"hasAdminPriorityOnWorkflow":false,"hasManuscriptDocX":false,"hasOptedInToPreprint":true,"hasPassedJournalQc":"","hasAnyPriority":false,"hideJournal":true,"highlight":"","institution":"","isAcceptedByJournal":false,"isAuthorSuppliedPdf":true,"isDeskRejected":"","isHiddenFromSearch":false,"isInQc":false,"isInWorkflow":false,"isPdf":true,"isPdfUpToDate":true,"isWithdrawnOrRetracted":false,"journal":{"display":true,"email":"[email protected]","identity":"researchsquare","isNatureJournal":false,"hasQc":true,"allowDirectSubmit":true,"externalIdentity":"","sideBox":"","snPcode":"","submissionUrl":"/submission","title":"Research Square","twitterHandle":"researchsquare","acdcEnabled":true,"dfaEnabled":false,"editorialSystem":"","reportingPortfolio":"","inReviewEnabled":false,"inReviewRevisionsEnabled":true},"keywords":"Ultrasonic-Assisted Milling (UAM), Conventional Milling (CM), Cutting Force, Residual Stress, Distortion, Surface Integrity, Finite Element Simulation, Experimental Analysis, Aluminum 7075","lastPublishedDoi":"10.21203/rs.3.rs-6486120/v1","lastPublishedDoiUrl":"https://doi.org/10.21203/rs.3.rs-6486120/v1","license":{"name":"CC BY 4.0","url":"https://creativecommons.org/licenses/by/4.0/"},"manuscriptAbstract":"\u003cp\u003eThe cutting forces, residual stresses, and workpiece distortion in machining processes largely influence the quality of the end product. An advanced technique for the amelioration of these parameters is ultrasonic-assisted milling (UAM), which induces high-frequency vibrations onto the cutting tool to intermittently disrupt tool-workpiece contact, aiding in the removal of material more effectively. This study focuses on ultrasonic-assisted milling and its effects on cutting forces, workpiece distortion, tensile residual stress, and surface integrity via finite element simulation and experimental approaches. A numerical model was built in ABAQUS first and validated against experimental observations. In the experiments, aluminum 7075 was selected as the workpiece material, and various machining parameters including spindle speed, feed rate, and milling method were investigated. The results indicated that UAM reduced cutting forces up to 25%, workpiece distortion of 21.5%, and tensile residual stresses by 23% compared to conventional milling (CM). Microscopic investigations revealed better surface integrity in the UAM compared to CM, as trace scratches were less and there were fewer surface defects. The comparison between simulations and experimental findings also yielded good correlation with a deviation in output parameters within 11%. This finding demonstrates that ultrasonic-assisted milling is an effective method for improving dimensional accuracy and surface quality in the machining process.\u003c/p\u003e","manuscriptTitle":"A novel finite element simulation approach for analyzing distortion and residual stress in ultrasonic-assisted milling","msid":"","msnumber":"","nonDraftVersions":[{"code":1,"date":"2025-05-06 18:25:27","doi":"10.21203/rs.3.rs-6486120/v1","editorialEvents":[{"type":"communityComments","content":0}],"status":"published","journal":{"display":true,"email":"[email protected]","identity":"researchsquare","isNatureJournal":false,"hasQc":true,"allowDirectSubmit":true,"externalIdentity":"","sideBox":"","snPcode":"","submissionUrl":"/submission","title":"Research Square","twitterHandle":"researchsquare","acdcEnabled":true,"dfaEnabled":false,"editorialSystem":"","reportingPortfolio":"","inReviewEnabled":false,"inReviewRevisionsEnabled":true}}],"origin":"","ownerIdentity":"c618985f-13a3-4fb2-97d8-6ad0b45b87ea","owner":[],"postedDate":"May 6th, 2025","published":true,"recentEditorialEvents":[],"rejectedJournal":[],"revision":"","amendment":"","status":"posted","subjectAreas":[],"tags":[],"updatedAt":"2025-06-19T11:24:07+00:00","versionOfRecord":[],"versionCreatedAt":"2025-05-06 18:25:27","video":"","vorDoi":"","vorDoiUrl":"","workflowStages":[]},"version":"v1","identity":"rs-6486120","journalConfig":"researchsquare"},"__N_SSP":true},"page":"/article/[identity]/[[...version]]","query":{"redirect":"/article/rs-6486120","identity":"rs-6486120","version":["v1"]},"buildId":"8U1c8b4HqxoKbykW_rLl7","isFallback":false,"isExperimentalCompile":false,"dynamicIds":[84888],"gssp":true,"scriptLoader":[]}