Ultrasonic longitudinal vibration assisted helical milling (ULVAHM) can significantly improve the machining quality. However

the complex kinematics can result in a more complex morphology of the surface machined by ULVAHM than that by a conventional helical milling. To predict the morphology and summarize the rules of the machined surface generated by ULVAHM

a morphology prediction model and its visualization method were proposed in this study

and a verification experiment was conducted to compare the three typical microscopic characteristics

namely

wave texture

sharp-like peak and segmented layer. A favorable agreement between experimental and simulation results was demonstrated. Afterwards

the effects of amplitude

rotational speed

revolution feed and tangential feed on the surface morphology were evaluated by using the model. The investigation results show that the amplitude in ultrasonic vibration leads to the formation of wavy patterns on sidewalls. As the spindle speed increases

the wavy pattern weave becomes sparser. Meanwhile

the height of oblique crest band

the spacing of split layers

and the height of shaped projection are determined by the circumferential feed per tooth

axial feed per tooth

and feed speed

respectively.