scholarly journals A mechanistic model on feeding-directional cutting force in surface grinding of CFRP composites using rotary ultrasonic machining with horizontal ultrasonic vibration

2019 ◽  
Vol 155 ◽  
pp. 450-460 ◽  
Author(s):  
Hui Wang ◽  
Yingbin Hu ◽  
Weilong Cong ◽  
Zhonglue Hu
Keyword(s):  
Cutting Force ◽  
Ultrasonic Vibration ◽  
Mechanistic Model ◽  
Surface Grinding ◽  
Ultrasonic Machining ◽  
Rotary Ultrasonic Machining ◽  
Cfrp Composites

Surface Grinding of CFRP Composites Using Rotary Ultrasonic Machining: Effects of Ultrasonic Power

2017 ◽  
Author(s):  
Hui Wang ◽  
Yingbin Hu ◽  
Fuda Ning ◽  
Yuzhou Li ◽  
Meng Zhang ◽  
...  
Keyword(s):  
Cutting Force ◽  
Weight Ratio ◽  
High Strength ◽  
Surface Grinding ◽  
Future Research ◽  
Ultrasonic Power ◽  
Ultrasonic Machining ◽  
Rotary Ultrasonic Machining ◽  
Grinding Processes ◽  
Cfrp Composites

Carbon fiber reinforced plastic (CFRP) composites have superior properties, including high strength-to-weight ratio, high modulus-to-weight ratio, high fatigue resistance, etc. These properties make CFRP composites being popular in many kinds of industries. Due to the inhomogeneous and anisotropic properties, and high abrasiveness of the reinforcement in CFRP composites, they are classified as difficult-to-cut materials in surface grinding processes. Many problems (including high cutting force and low machining efficiency) are generated in conventional surface grinding processes. In order to reduce and eliminate these problems, rotary ultrasonic machining (RUM) surface grinding of CFRP composites is conducted in this investigation. Effects of ultrasonic power in different machining levels are of great importance in RUM surface grinding processes. However, no investigations on effects of ultrasonic power in different machining levels are conducted in such a process. This investigation, for the first time, tests the effects of ultrasonic power on output variables, including cutting force, torque, and surface roughness in different machining levels. This paper will provide guides for future research on effects of ultrasonic power in different combinations of machining variables on output variables.

Delamination in Surface Machining of CFRP Composites Using Rotary Ultrasonic Machining With Horizontal Ultrasonic Vibration

2020 ◽  
Author(s):  
Hui Wang ◽  
Dongzhe Zhang ◽  
Yunze Li ◽  
Weilong Cong ◽  
Anthony R. Burks
Keyword(s):  
Surface Roughness ◽  
Cutting Force ◽  
Ultrasonic Vibration ◽  
Rotation Speed ◽  
Depth Of Cut ◽  
Ultrasonic Machining ◽  
Rotary Ultrasonic Machining ◽  
Surface Machining ◽  
Tool Rotation Speed ◽  
Tool Rotation

Abstract Surface machining of carbon fiber reinforced plastic (CFRP) using rotary ultrasonic machining (RUM) with vertical ultrasonic vibration was effective in reducing many issues, including high cutting force, high torque, and high tool wear rate. The vertical ultrasonic vibration also induced damages to machined CFRP surfaces and then resulted in increased surface roughness. To simultaneously decrease surface roughness and cutting force, the direction of ultrasonic vibration needed to be parallel with the surface generation direction (horizontal feeding direction). The horizontal ultrasonic vibration was then developed and applied for RUM surface machining of CFRP. The application of horizontal ultrasonic vibration in RUM surface machining produced simultaneously decreased surface roughness and cutting force. However, there were no investigations on delamination in such a process, and delamination was considered as one of the major factors to reject the machined CFRP products. This investigation would study the delamination under different machining-variable groups, the delamination generation mechanisms, and the relationships between delamination and cutting forces through the experimental method in surface machining of CFRP using RUM with horizontal ultrasonic vibration. Smaller cutting force and delamination thickness would be produced by the smaller depth of cut, smaller feedrate, or larger tool rotation speed. Smaller indentation depth was generated by larger tool rotation speed or smaller feedrate. Smaller material removal rate and abrasive-grain number taking part in the cutting process were produced by the smaller depth of cut. The delamination initiation at larger uncut CFRP thickness would be induced by higher cutting force.

Ultrasonic-Vibration-Assisted Grinding of Brittle Materials: A Mechanistic Model for Cutting Force

2011 ◽  
Author(s):  
Na Qin ◽  
Z. J. Pei ◽  
W. L. Cong ◽  
C. Treadwell ◽  
D. M. Guo
Keyword(s):  
Cutting Force ◽  
Ultrasonic Vibration ◽  
Material Removal ◽  
Mechanistic Model ◽  
Brittle Materials ◽  
Rotary Ultrasonic Machining ◽  
Input Variables ◽  
Diamond Grain ◽  
First Time ◽  
Ultrasonic Vibration Assisted Grinding

A mechanistic model for cutting force in ultrasonic-vibration-assisted grinding (UVAG) (also called rotary ultrasonic machining) of brittle materials is proposed for the first time. Fundamental assumptions include: (1) brittle fracture is the dominant mechanism of material removal, and (2) the removed volume by each diamond grain in one vibration cycle can be related to its indentation volume in the workpiece through a mechanistic parameter. Experiments with UVAG of silicon are conducted to determine the mechanistic parameter for silicon. With the developed model, influences of six input variables on cutting force are predicted. These predicted influences trends are also compared with those determined experimentally for several brittle materials.

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