Rotary Ultrasonic Machining–New Strategy of Cutting and Finishing

2020 ◽  
pp. 53-70
Author(s):  
S. Kumar ◽  
S. Das ◽  
B. Doloi ◽  
B. Bhattacharyya
Keyword(s):  
Ultrasonic Machining ◽  
Rotary Ultrasonic Machining ◽  
New Strategy

A Mechanistic Approach to the Prediction of Material Removal Rates in Rotary Ultrasonic Machining

1995 ◽  
Vol 117 (2) ◽  
pp. 142-151 ◽  
Author(s):  
Z. J. Pei ◽  
D. Prabhakar ◽  
P. M. Ferreira ◽  
M. Haselkorn
Keyword(s):  
Material Removal Rate ◽  
Material Removal ◽  
Removal Rate ◽  
Diamond Particle ◽  
Machining Parameters ◽  
Ultrasonic Machining ◽  
Rotary Ultrasonic Machining ◽  
Stabilized Zirconia ◽  
Mechanistic Approach ◽  
Wide Range

An approach to modeling the material removal rate (MRR) during rotary ultrasonic machining (RUM) of ceramics is proposed and applied to predicting the MRR for the case of magnesia stabilized zirconia. The model, a first attempt at predicting the MRR in RUM, is based on the assumption that brittle fracture is the primary mechanism of material removal. To justify this assumption, a model parameter (which models the ratio of the fractured volume to the indented volume of a single diamond particle) is shown to be invariant for most machining conditions. The model is mechanistic in the sense that this parameter can be observed experimentally from a few experiments for a particular material and then used in prediction of MRR over a wide range of process parameters. This is demonstrated for magnesia stabilized zirconia, where very good predictions are obtained using an estimate of this single parameter. On the basis of this model, relations between the material removal rate and the controllable machining parameters are deduced. These relationships agree well with the trends observed by experimental observations made by other investigators.

The Research and Development on the Material Removal Mechanism of the Ultrasonic Cutting

2014 ◽  
Vol 1027 ◽  
pp. 40-43
Author(s):  
Yan Yan Lou ◽  
Yan Zhang ◽  
Ying Gao ◽  
Jia Chen Zhang ◽  
Yan Zhou Sun
Keyword(s):  
Material Removal ◽  
Development Trend ◽  
Ultrasonic Machining ◽  
Removal Mechanism ◽  
Rotary Ultrasonic Machining ◽  
Material Removal Mechanism ◽  
Material Removal Model ◽  
The Development Trend ◽  
Removal Model ◽  
Ultrasonic Cutting

Ultrasonic machining is an important part of modern processing technology which is adapt to all kinds of hard brittle materials processing. This paper reviews the latest progress of the material removal mechanism on one-dimensional ultrasonic machining, two-dimensional ultrasonic machining and rotary ultrasonic machining, and expounds the development trend of establishing the material removal model of the ultrasonic machining.

Rotary Ultrasonic Machining: Effects of Tool End Angle on Delamination of CFRP Drilling

2017 ◽  
Author(s):  
Palamandadige K. S. C. Fernando ◽  
Meng (Peter) Zhang ◽  
Zhijian Pei ◽  
Weilong Cong
Keyword(s):  
Carbon Fiber ◽  
Material Removal ◽  
Ultrasonic Machining ◽  
Fiber Reinforced ◽  
Rotary Ultrasonic Machining ◽  
Carbon Fiber Reinforced Plastics ◽  
Reinforced Plastics ◽  
Hole Making ◽  
Fiber Reinforced Plastics ◽  
Carbon Fiber Reinforced

Aerospace, automotive and sporting goods manufacturing industries have more interest on carbon fiber reinforced plastics due to its superior properties, such as lower density than aluminum; higher strength than high-strength metals; higher stiffness than titanium etc. Rotary ultrasonic machining is a hybrid machining process that combines the material removal mechanisms of diamond abrasive grinding and ultrasonic machining. Hole-making is the most common machining operation done on carbon fiber reinforced plastics, where delamination is a major issue. Delamination reduces structural integrity and increases assembly tolerance, which leads to rejection of a part or a component. Comparatively, rotary ultrasonic machining has been successfully applied to hole-making in carbon fiber reinforced plastics. As reported in the literature, rotary ultrasonic machining is superior to twist drilling of carbon fiber reinforced plastics in six aspects: cutting force, torque, surface roughness, delamination, tool life, and material removal rate. This paper investigates the effects of tool end angle on delamination in rotary ultrasonic machining of carbon fiber reinforced plastics. Several investigators have cited thrust force as a major cause for delamination. Eventhogh, it is found on this investigation, tool end angle has more significant influence on the delamination in rotary ultrasonic machining of carbon fiber reinforced plastics comparing to cutting force and torque.

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