scholarly journals Cutting force and specific energy for rotary ultrasonic drilling based on kinematics analysis of vibration effectiveness

2021 ◽  
Author(s):  
Zhen LI ◽  
Songmei YUAN ◽  
Jiang MA ◽  
Jun SHEN ◽  
Andre D.L. BATAKO
Keyword(s):  
Cutting Force ◽  
Specific Energy ◽  
Kinematics Analysis ◽  
Ultrasonic Drilling ◽  
Rotary Ultrasonic Drilling

Design of a Novel Air Bearing Workbench for Rotary Ultrasonic Drilling of Advanced Ceramics

2012 ◽  
Vol 134 (9) ◽  
Author(s):  
Liping Liu ◽  
Bin Lin ◽  
Fengzhou Fang
Keyword(s):  
Finite Element Method ◽  
Finite Element ◽  
Bearing Capacity ◽  
Cutting Force ◽  
Air Bearing ◽  
The Novel ◽  
Advanced Ceramics ◽  
Air Damping ◽  
Ultrasonic Drilling ◽  
Rotary Ultrasonic Drilling

A novel air bearing workbench used in rotary ultrasonic drilling of advanced ceramics was designed to constantly and sensitively control the cutting force. Compared with traditional feed systems, the novel air bearing workbench features an aerostatic guide and a pneumatic actuator, so that it only overcomes the air damping when the cutting force is balanced. Thus, it can sensitively and constantly control the cutting force for rotary ultrasonic drilling of advanced ceramics. The aerostatic guide, which determines the eccentric bearing capacity and stiffness of the workbench, is the most important part. The forces applied on the aerostatic guide faces were analyzed to calculate the bearing capacity and stiffness of the workbench using varying gas film thicknesses with finite element method (FEM). Based on the result of the analysis, the best gas film thickness of the aerostatic guide was designed to be 30 μm. The real eccentric bearing capacity and stiffness of the workbench were measured. The error between experimental results and the FEM results was within 12%.

A Mathematical Model for Predicting Cutting Force in Rotary Ultrasonic Drilling

2012 ◽  
Vol 433-440 ◽  
pp. 2034-2041 ◽  
Author(s):  
Cheng Long Zhang ◽  
Ping Fa Feng ◽  
Zhi Jun Wu ◽  
Ding Wen Yu
Keyword(s):  
Mathematical Model ◽  
Cutting Force ◽  
Machining Process ◽  
Computation Method ◽  
Force Model ◽  
Machining Parameters ◽  
Ultrasonic Machining ◽  
Rotary Ultrasonic Machining ◽  
Ultrasonic Drilling ◽  
Rotary Ultrasonic Drilling

Rotary ultrasonic machining is a hybrid machining process that combines diamond grinding and ultrasonic machining. The mathematical predictive material removal rate models have been developed in rotary ultrasonic machining with a constant pressure. However, there is no report on mathematical predictive cutting force model in rotary ultrasonic drilling at a constant feedrate presently. Since cutting force can not only reflect the processing state, but also affect the machined surface quality, it is necessary to develop a mathematical model for predicting cutting force which can forecast the machining results. This paper presents a mathematical model to predict the cutting force in rotary ultrasonic machining. On the basis of this model, the relations between cutting force and controllable machining parameters are researched by numerical computation method. This paper also researches the influences of spindle speed and feedrate on cutting force by experiments. The results observed through the experiments agree well with the relations generated from the mathematical model, which verify the developed model.

An Experimental Study on Processing Performance of Rotary Ultrasonic Drilling of K9 Glass

2011 ◽  
Vol 230-232 ◽  
pp. 221-225 ◽  
Author(s):  
Cheng Long Zhang ◽  
Ping Fa Feng ◽  
Zhi Jun Wu ◽  
Ding Wen Yu
Keyword(s):  
Surface Roughness ◽  
Cutting Force ◽  
Diamond Particle ◽  
Machining Process ◽  
Cutting Depth ◽  
Ultrasonic Drilling ◽  
Cutting Length ◽  
Cutting Velocity ◽  
Rotary Ultrasonic Drilling ◽  
K9 Glass

Rotary ultrasonic machining process, regarded as one of the effective processing methods for hard-brittle materials, is introduced into drilling K9 glass in this paper. The effective cutting velocity, cutting depth, and cutting length of single diamond particle are determined by analyzing the kinematics characteristic of diamond tool in rotary ultrasonic drilling (RUD). Experiments are conducted to study the influences of process variables (spindle speed, feedrate) on cutting force, chipping size, and surface roughness in RUD. As comparison study, the processing performances between RUD and diamond drilling are also discussed. The experimental results show that the RUD process can significantly reduce cutting force and the value of chippings size, which inferred that RUD process can improve machining efficiency and make the machining cost lower. It is also concluded that the effective cutting depth of diamond particles is the main factor for surface roughness in RUD of K9 glass.

Experimental Examination of the Impact of Tool Radius on Specific Energy in Microcutting of Granite

2017 ◽  
Vol 139 (4) ◽  
Author(s):  
Miloš Pjević ◽  
Ljubodrag Tanović ◽  
Goran Mladenović ◽  
Biljana Marković
Keyword(s):  
Cutting Force ◽  
Penetration Depth ◽  
Specific Energy ◽  
Brittle Materials ◽  
Experimental Examination ◽  
Workpiece Surface ◽  
Different Shapes ◽  
Tip Radius ◽  
The Impact ◽  
Force Intensity

The paper presents experimental results of microcutting brittle materials (granite). The analysis was conceived on the observed interaction between the workpiece and two tools of different shapes. Experiment was based on scratching the workpiece surface with diamond tools. Applied tools had tip radius R0.2 and R0.15 mm. The experiment determined the changes in the value of perpendicular and tangential components of the cutting force based on the geometric properties of tools, as well as the changes of the specific energy of microcutting granite (Jošanica and Bukovik types). The experiment has shown that reduction of tool radius causes reduction of the cutting force intensity and specific cutting energy. Because of its physical/mechanical properties, more energy is required for micromachining granite “Jošanica” than “Bukovik.” Based on the topography of the surface, the value of critical tool penetration depth was established, after which the brittle fracture is no longer present. For granite “Jošanica” values of critical penetration depth are 6 and 5 μm when micromachining with tools R0.2 and R0.15 mm, while for Bukovik those values are 6.5 and 5.5 μm. The paper should form the basis for understanding the phenomena which occur during microcutting brittle materials.

scholarly journals Precise Drilling of Holes in Alumina Ceramic (Al2O3) by Rotary Ultrasonic Drilling and its Parameter Optimization using MOGA-II

Materials ◽  
2020 ◽  
Vol 13 (5) ◽  
pp. 1059 ◽  
Author(s):  
Hisham Alkhalefah
Keyword(s):  
Feed Rate ◽  
Dimensional Accuracy ◽  
Alumina Ceramic ◽  
Process Variables ◽  
Multi Objective Genetic Algorithm ◽  
Ultrasonic Drilling ◽  
Drilling Quality ◽  
Processing Techniques ◽  
Validation Tests ◽  
Rotary Ultrasonic Drilling

Alumina is an advanced ceramic with applications in dental and medical sciences. Since ceramics are hard and brittle, their conventional machining is expensive, arduous, and time-consuming. As rotary ultrasonic machining is among the most adequate and proficient processing techniques for brittle materials like ceramics. Therefore, in this study, rotary ultrasonic drilling (RUD) has been utilized to drill holes on alumina ceramic (Al2O3). This study investigates the effect of key RUD process variables, namely vibration frequency, vibration amplitude, spindle speed, and feed rate on the dimensional accuracy of the drilled holes. A four-variable three-level central composite design (thirty experiments on three sample plates) is utilized to examine the comparative significance of different RUD process variables. The multi-objective genetic algorithm is employed to determine the optimal parametric conditions. The findings revealed that material removal rates depend on feed rate, while the cylindricity of the holes is mostly controlled by the speed and feed rate of the spindles. The optimal parametric combination attained for drilling quality holes is speed = 4000 rpm, feed rate = 1.5 (mm/min), amplitude = 20 (µm), and frequency = 23 (kHz). The validation tests were also conducted to confirm the quality of drilled holes at the optimized process parameters.

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