Enhancing material removal processes using modulation-assisted machining

The controlled application of low-frequency modulation to machining – Modulation Assisted Machining (MAM) – is shown to effect discrete chip formation and disrupt the severe contact condition at the tool–chip interface. This enables chips of different morphologies, including discrete-particle like chips, to be created, and prescription of the machined surface texture. A model for MAM is used to describe chip formation regimes and textures. Benefits include improved chip management; enhanced lubrication; reduction of tool wear; and enhanced material removal rates. Prototype implementation of MAM in processes such as drilling and turning is described in case studies.