Modeling the dependency of edge chipping size on the material properties and cutting force for rotary ultrasonic drilling of brittle materials

2016 ◽  
Vol 101 ◽  
pp. 18-27 ◽  
Author(s):  
Jianjian Wang ◽  
Pingfa Feng ◽  
Jianfu Zhang ◽  
Chenglong Zhang ◽  
Zhijian Pei
Keyword(s):  
Cutting Force ◽  
Material Properties ◽  
Brittle Materials ◽  
Edge Chipping ◽  
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%.

scholarly journals Application of Numerical Simulation for the Analysis of the Processes of Rotary Ultrasonic Drilling

2016 ◽  
Vol 24 (39) ◽  
pp. 151-158
Author(s):  
Milan Naď ◽  
Lenka Čičmancová ◽  
Štefan Hajdu
Keyword(s):  
Numerical Simulation ◽  
Resonance State ◽  
Hole Drilling ◽  
Ultrasonic Machining ◽  
Rotary Ultrasonic Machining ◽  
Final Phase ◽  
Machining Performance ◽  
Edge Chipping ◽  
Ultrasonic Drilling ◽  
Rotary Ultrasonic Drilling

Abstract Rotary ultrasonic machining (RUM) is a hybrid process that combines diamond grinding with ultrasonic machining. It is most suitable to machine hard brittle materials such as ceramics and composites. Due to its excellent machining performance, RUM is very often applied for drilling of hard machinable materials. In the final phase of drilling, the edge deterioration of the drilled hole can occur, which results in a phenomenon called edge chipping. During hole drilling, a change in the thickness of the bottom of the drilled hole occurs. Consequently, the bottom of the hole as a plate structure is exposed to the transfer through the resonance state. This resonance state can be considered as one of the important aspects leading to edge chipping. Effects of changes in the bottom thickness and as well as the fillet radius between the wall and bottom of the borehole on the stress-strain states during RUM are analyzed.

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.

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