Rotary ultrasonic machining: effects of tool natural frequency on ultrasonic vibration amplitude

2019 ◽  
Vol 23 (4) ◽  
pp. 595-611 ◽  
Author(s):  
Palamandadige Kasun Shashika Chathu Fernando ◽  
Meng Zhang ◽  
Zhijian Pei
Keyword(s):  
Natural Frequency ◽  
Ultrasonic Vibration ◽  
Vibration Amplitude ◽  
Ultrasonic Machining ◽  
Rotary Ultrasonic Machining

scholarly journals Enhancement of surface roughness for brittle material during rotary ultrasonic machining

2018 ◽  
Vol 249 ◽  
pp. 01006 ◽  
Author(s):  
Ankit Sharma ◽  
Atul Babbar ◽  
Vivek Jain ◽  
Dheeraj Gupta
Keyword(s):  
Surface Roughness ◽  
Feed Rate ◽  
Vibration Amplitude ◽  
Research Study ◽  
Float Glass ◽  
Spindle Speed ◽  
Ultrasonic Machining ◽  
Rotary Ultrasonic Machining ◽  
Hole Quality ◽  
The Core

Surface roughness is the key aspect which could increase the application of float glass by enhancing the machined hole quality. Glass is extensively used in microfluidic devices, bio-medical parts and biosensors. The core objective of the research study is to optimize the best parametric combination to achieve the least amount of surface roughness. The three major parameters which are used for designed experimental study are spindle speed, ultrasonic amplitude and feed rate. The least value of surface roughness is noticed at spindle speed (5000 rpm), vibration amplitude (20 μ m) and feed rate (6 mm/min) which be adopted for increasing its functional application. Consequently, after optimizing the parameters, least value of surface roughness at hole internal region is revealed as 1.09 μm.

Experimental Investigation on Surface/Subsurface Damage in Rotary Ultrasonic Machining of Glass BK7

2013 ◽  
Vol 325-326 ◽  
pp. 1357-1361 ◽  
Author(s):  
Yan Hua Huang ◽  
Dong Xi Lv ◽  
Yong Jian Tang ◽  
Hong Xiang Wang ◽  
Hai Jun Zhang
Keyword(s):  
Surface Roughness ◽  
Ultrasonic Vibration ◽  
Process Parameters ◽  
Subsurface Damage ◽  
Spindle Speed ◽  
Feed Speed ◽  
Ultrasonic Machining ◽  
Rotary Ultrasonic Machining ◽  
Cutting Depth ◽  
Influence Of Process Parameters

Experiments were carried out to study the effect of ultrasonic vibration on the surface roughness and subsurface damage (SSD) in rotary ultrasonic machining (RUM) of glass BK7. As a comparison, some conventional grinding (CG) experiments were also performed under the same process parameters with there of the RUM ones. The surface roughness of the RUM/CG samples was measured with a surface profilometer. The SSD of these specimens was assessed and characterized by a measuring microscope with the help of the taper polishing method. Also, the influence of process parameters (cutting depth, feed speed, and spindle speed) on the surface/subsurface quality was discussed. As a result, both the surface roughness and the SSD depth of the RUM/CG specimens were reduced with the increased spindle speed, while increased with the increasing of feed speed and cutting depth of the diamond tool. Compared with the CG process, the introduction of ultrasonic vibration resulted in the higher surface roughness and SSD depth, due to the fact that the max cutting depth of the abrasive in the RUM process increased by an amplitude compared with that in the CG process.

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.

Surface Grinding of Optical BK7/K9 Glass Using Rotary Ultrasonic Machining: An Experimental Study

2017 ◽  
Author(s):  
Yingbin Hu ◽  
Hui Wang ◽  
Fuda Ning ◽  
Weilong Cong ◽  
Yuzhou Li
Keyword(s):  
Ultrasonic Vibration ◽  
Cutting Forces ◽  
Surface Grinding ◽  
Grinding Process ◽  
Ultrasonic Power ◽  
Ultrasonic Machining ◽  
Rotary Ultrasonic Machining ◽  
Edge Chipping ◽  
Torque Values ◽  
K9 Glass

BK7/K9 glass is regarded as a difficult-to-machine material due to its high hardness and high brittleness properties as well as high tool wear rate during machining. Facing to these challenges, an efficient and effective rotary ultrasonic machining (RUM) process, consisting of grinding process and ultrasonic machining process, was provided to process BK7/K9 glass. In this investigation, the effects of ultrasonic power on cutting forces, torque, and edge chipping of surface grinding in RUM of BK7/K9 glass were studied. Results showed that, by introducing ultrasonic vibration to surface grinding process, both cutting forces in feeding direction and in axial direction as well as torque values were reduced. The higher the ultrasonic power was, the lower the forces and torque values would be. Edge chipping, which was detrimental to the qualities of machined slots and would cause high machining cost, was significant reduced with the help of ultrasonic vibration.

Rotary Ultrasonic Machining of Alumina Dental Ceramics: A Preliminary Experimental Study on Surface and Subsurface Damages

2012 ◽  
Vol 134 (6) ◽  
Author(s):  
Yasser Ahmed ◽  
W. L. Cong ◽  
Matthew R. Stanco ◽  
Z. G. Xu ◽  
Z. J. Pei ◽  
...  
Keyword(s):  
Experimental Study ◽  
Electron Microscope ◽  
Ultrasonic Vibration ◽  
Dental Ceramics ◽  
Ultrasonic Machining ◽  
Rotary Ultrasonic Machining ◽  
Machined Surface ◽  
Subsurface Cracks ◽  
Preliminary Study ◽  
Scanning Electron

This paper presents a preliminary study about effects of ultrasonic vibration on machined surface and subsurface damages in rotary ultrasonic machining (RUM). The surface and subsurface damages are compared for machining of dental ceramics (Al2O3) with and without ultrasonic vibration. The surface chippings are evaluated and the subsurface cracks are observed under scanning electron microscope (SEM).

Vibration Amplitude in Rotary Ultrasonic Machining: A Novel Measurement Method and Effects of Process Variables

2011 ◽  
Vol 133 (3) ◽  
Author(s):  
W. L. Cong ◽  
Z. J. Pei ◽  
N. Mohanty ◽  
E. Van Vleet ◽  
C. Treadwell
Keyword(s):  
Vibration Amplitude ◽  
Measurement Method ◽  
Experimental Results ◽  
Ultrasonic Power ◽  
Ultrasonic Machining ◽  
Process Variables ◽  
Rotary Ultrasonic Machining ◽  
Workpiece Material ◽  
Ductile Materials ◽  
First Time

Rotary ultrasonic machining (RUM) has been used to machine both brittle and ductile materials as well as composite materials. There are numerous reported studies about the effects of various process variables on output responses. However, the current literature contains few articles about the measurement methods of vibration amplitude in RUM and about the effects of process variables on vibration amplitude. The lack of such knowledge has made it difficult to explain some experimentally observed phenomena in RUM and degraded the creditability of some experimental results with RUM. This paper, for the first time, presents a measurement method capable of measuring vibration amplitude during RUM machining. It also reports RUM experimental results on effects of cutting tool, ultrasonic power, workpiece material, tool rotation speed, and feedrate on ultrasonic amplitude. This study will fill some blanks in the literature and provide plausible explanations to some seemingly contradictory results reported in the literature.

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