Manufacture of overhanging sharp corner by means of 6-axis control machining with the application of ultrasonic vibrations

The study proposes a new machining method to create an overhanging sharp corner. Sharp corners on overhanging surfaces are difficult to machine in conventional way or even in 3 to 5-axis EDM especially if the surfaces have different angles. This, is due to the limitation of the feed direction and the structure of the electrode wherein it must be symmetrical with the target shape. In present research, we try to machine the sharp corner with overhanging surfaces using the new machining method. The 6-axis control machining is applied to set a non-rotational tool at an arbitrary position with arbitrary attitude against the workpiece. During cutting, the ultrasonic vibration is applied on the cutting edge of the tool, while the tool travels along the feed direction. As the cutting is performed, the 6 axes (X, Y, Z, A, B, and C) move simultaneously, depending on the tool attitude at a certain cutting point. From the experimental results, it is shown that the 6-axis control ultrasonic vibration cutting is capable of producing a sharp corner on overhanging surfaces.