[en] Sustainable development for machining strategies, process, and technologies, is compulsory in the industries. Machining surface quality improvement and the extension of tool life-time are commonly set as goals by many researchers, in the fulfilment of that sustainable development. Unforeseen and uncontrollable vibration or known as passive vibration is an unavoidable effect and a menace in machining. However in contrary, adding active vibration with stable frequency and amplitude, and small depth of cut during machining, give positive impact toward machine performance and surface quality. Vibration Assisted Machining (VAM) generates active vibration on the tool or workpiece. That vibration repeatedly causes tool-workpiece separation for a period of time during machining. The tool-workpiece separation is the main reason of VAM advancements. Adding VAM to conventional machining requires further consideration in term of design and cutting method, which are investigated in this comprehensive literature review. Critical aspect in adding VAM to micro milling machine was also discussed. (paper)

[en] In recent years, the rapid technology development in industry sector, especially in aviation industry has been increasing. So that we need more capabilities in the micro-scale manufacturing process, especially micro-milling process which can produce good surface roughness and high complexity parts. In this study, the effect of machining parameters to the surface roughness investigated by using Inconel 718 material with cutting tool diameter 1 mm, carbide material with coating TiAlN. The machining process was performed in low speed machining category. There are three variations of spindle speed (3.000, 7.000, 10.000 RPM) and also feed rate (0.5, 1, 2 mm/s) with constant depth of cut 10 μm. The relationship between machining parameters and surface roughness was obtained. The higher the feed rate, the higher the surface roughness produced. On the other hand, the higher the spindle speed the smaller the surface roughness. It also found that the machining process with low spindle speed, below 10.000 RPM, successfully carried out on hard-to-cut material, Inconel 718, that will be increasing the flexibility of machining parameters. (paper)

[en] The demand for micro-scale products is increasing rapidly in various fields of industries such as electronics, bio-medical, optical industry, and so on. Titanium alloys especially Ti-6Al-4V is one of the commonly used in bio-medical industries because of its biocompability properties. However, poor surface quality in terms of surface roughness commonly occurs because of unappropriate cutting parameters to machine this hard to cut material. This study aims to investigate the influencing machining parameters to produce micro-products with a low level of surface roughness in Titanium Alloy (Ti-6Al-4V) material using a miniaturized micro-milling machine. Experiments carried out by micromilling process with variations in low rpm spindle speed and feed rate with a constant depth of cut using a carbide cutting tool of with a diameter of 1 mm. The machining results in the form of a 4 mm slot with a depth of 10 μm, which then measures its surface roughness. It was found that as the feed rate increases, the surface roughness also accordingly increases. On the other hand, the surface roughness decreases as the spindle speed increases. (paper)

[en] The needs of miniaturized products have increased a lot in this ever-changing world. This makes the micromanufacturing technologies develop fast in order to keep up with this higher needs and to meet the required quality of a product. One of the developed technologies is ultrasonic vibration assisted machining (UVAM). UVAM is different than conventional machining because of the way the cutting tool move relative to the workpiece. This different cutting phenomenon produces a different chip geometry than the conventional machining. The purpose of this paper is to give an understanding through chip geometry models about how UVAM can be a better cutting method rather than conventional milling. MATLAB is used in order to do the modelling of theoretical chip geometry. The approach used in this study is by calculating where the cutting tool edge is in a given unit of time before and after the ultrasonic vibration is induced to the workpiece in X-Y dimension. A characteristic in the cutting edge called the bottom cutting edge angle is also considered. By comparing the two chip geometries, some benefits that UVAM gives are explained. (paper)

[en] The purpose of this study is to design and develop a Two-Dimensional Ultrasonic Vibration Assisted Micro-milling (2D UVAMM) system. Two-dimensional ultrasonic vibrations produced by 2D UVAMM are used to vibrate the workpiece in the micro-milling process. The system is developed using the principle of two Langevin piezoelectric transducers which have the ability to produce ultrasonic vibrations with small vibration amplitude. Process of 2D UVAMM design optimization was done by modal simulation using Finite Element Analysis method. Both Langevin piezoelectric transducers are designed to have symmetrical and asymmetrical vibration modes with the same natural frequency, so that elliptical pattern vibrations can be generated on the workpiece. The 2D UVAMM system operates at a natural frequency of 24 kHz and has an estimated total displacement on the normal and tangential axes respectively 0.766 μm and 0.382 μm. Two power sources with frequency of 24 kHz, phase difference of 90 degrees, and peak-peak voltage of 212 volt were supplied by an ultrasonic generator to excite both of the Langevin piezoelectric transducers. To confirm the developed 2D UVAMM system, experiments were conducted to compare the surface roughness of Aluminum 6061-T6 through micro-milling with conventional method and with additional of the 2D UVAMM system. (paper)