Fast Generation of Planar Microstructured Surfaces by Elliptical Vibration Texturing

2017 ◽  
Vol 5 (1) ◽  
Author(s):  
Yang Yang ◽  
Ping Guo
Keyword(s):  
Simulation Model ◽  
Functional Performance ◽  
Ultrasonic Frequency ◽  
Specific Class ◽  
High Productivity ◽  
Elliptical Vibration ◽  
Microstructured Surfaces ◽  
Elliptical Vibration Texturing ◽  
Cutting Velocity ◽  
Rapid Generation

Microstructured surfaces have extensive applications in a wide array of fields due to their improved functional performance. Existing manufacturing methods for these surfaces fall short of efficiency for volume production or are only applicable to a specific class of materials. In this paper, an innovative and highly efficient machining method, elliptical vibration texturing (EVT), is proposed for rapid generation of microdimples on planar engineered surfaces. The cutting tool of the EVT process vibrates along an elliptical trajectory. The elliptical vibrations, when coupled with a high cutting velocity, impose microdimples onto workpiece surfaces while machining. The high productivity is achieved by adopting a newly designed tertiary motion generator, which is able to deliver required elliptical vibrations at an ultrasonic frequency. The shape and distribution of the generated dimple patterns have been theoretically analyzed and predicted by a proposed simulation model. Preliminary texturing results using aluminum and brass as workpieces are given to validate the process principle and simulation model.

Fast Generation of Planar Micro-Structured Surfaces by Elliptical Vibration Texturing

2016 ◽  
Author(s):  
Yang Yang ◽  
Ping Guo
Keyword(s):  
Simulation Model ◽  
Functional Performance ◽  
Ultrasonic Frequency ◽  
Specific Class ◽  
Structured Surfaces ◽  
High Productivity ◽  
Elliptical Vibration ◽  
Elliptical Vibration Texturing ◽  
Cutting Velocity ◽  
Micro Dimples

Micro-structured surfaces have extensive applications in a wide array of fields, due to their improved functional performance. Existing manufacturing methods for these surfaces fall short of efficiency for volume production or are only applicable to a specific class of materials. In this paper, an innovative and highly-efficient machining method, elliptical vibration texturing (EVT), is proposed for rapid generation of micro-dimples on planar engineered surfaces. The cutting tool of the EVT process vibrates along an elliptical trajectory. The elliptical vibrations, when coupled with a high cutting velocity, impose micro-dimples onto workpiece surfaces while machining. The high productivity is achieved by adopting a newly designed tertiary motion generator which is able to deliver required elliptical vibrations at an ultrasonic frequency. The shape and distribution of the generated dimple patterns have been theoretically analyzed and predicted by a proposed simulation model. Preliminary texturing results using aluminum and brass as workpieces are given to validate the process principle and simulation model.

Experimental Study of Microgroove Surface Using Three-Dimensional Elliptical Vibration Texturing

2019 ◽  
Vol 7 (2) ◽  
Author(s):  
Rendi Kurniawan ◽  
Saood Ali ◽  
Ki Moon Park ◽  
Sang Tae Jung ◽  
Tae Jo Ko
Keyword(s):  
Experimental Study ◽  
Three Dimensional ◽  
Cutting Speed ◽  
Machined Surface ◽  
Elliptical Vibration ◽  
Microstructured Surface ◽  
Microstructured Surfaces ◽  
Elliptical Vibration Texturing ◽  
Preliminary Study ◽  
Cutting Speeds

This paper presents our preliminary study of the microstructured surface on microgrooves patterns, which have manufactured using the three-dimensional elliptical vibration texturing (3D-EVT) method. The 3D-EVT method uses a three-dimensional trajectory of elliptical locus of the cutting tool tip in high vibration frequency to fabricate the microstructure or the vibration mark pattern on the machined surface. The experimental study has been done with a variation of the nominal cutting speeds from 300 to 600 mm/min. The preliminary results showed that in the low nominal cutting speed of 300 and 450 mm/min, the microstructured surfaces were not manufactured well due to the bulging existence on the microstructured surface in which it is correlated with the build-up edge phenomena. On the other hand, a relative excellent microstructured surface can be achieved at the higher nominal cutting speed of 600 mm/min. In addition, a lubricant could be used to obtain an excellent microstructured surface to avoid the built-up edge phenomena.

scholarly journals A high-frequency non-resonant elliptical vibration-assisted cutting device for diamond turning microstructured surfaces

2021 ◽  
Vol 112 (11-12) ◽  
pp. 3247-3261
Author(s):  
Zhengjian Wang ◽  
Xichun Luo ◽  
Haitao Liu ◽  
Fei Ding ◽  
Wenlong Chang ◽  
...  
Keyword(s):  
Heat Generation ◽  
High Frequency ◽  
Diamond Turning ◽  
Coupling Ratio ◽  
Modal Characteristics ◽  
Elliptical Vibration ◽  
Microstructured Surfaces ◽  
Operational Frequency ◽  
The Cross ◽  
Cross Axis

AbstractIn recent years, research has begun to focus on the development of non-resonant elliptical vibration-assisted cutting (EVC) devices, because this technique offers good flexibility in manufacturing a wide range of periodic microstructures with different wavelengths and heights. However, existing non-resonant EVC devices for diamond turning can only operate at relatively low frequencies, which limits their machining efficiencies and attainable microstructures. This paper concerns the design and performance analysis of a non-resonant EVC device to overcome the challenge of low operational frequency. The structural design of the non-resonant EVC device was proposed, adopting the leaf spring flexure hinge (LSFH) and notch hinge prismatic joint (NHPJ) to mitigate the cross-axis coupling of the reciprocating displacements of the diamond tool and to combine them into an elliptical trajectory. Finite element analysis (FEA) using the mapped meshing method was performed to assist the determination of the key dimensional parameters of the flexure hinges in achieving high operational frequency while considering the cross-axis coupling and modal characteristics. The impact of the thickness of the LSFH on the sequence of the vibrational mode shape for the non-resonant EVC device was also quantitatively revealed in this study. Moreover, a reduction in the thickness of the LSFH can reduce the natural frequency of the non-resonant EVC device, thereby influencing the upper limit of its operational frequency. It was also found that a decrease in the neck thickness of the NHPJ can reduce the coupling ratio. Experimental tests were conducted to systematically evaluate the heat generation, cross-axis coupling, modal characteristics and diamond tool’s elliptical trajectory of a prototype of the designed device. The test results showed that it could operate at a high frequency of up to 5 kHz. The cross-axis coupling ratio and heat generation of the prototype are both at an acceptable level. The machining flexibility and accuracy of the device in generating microstructures of different wavelengths and heights through tuning operational frequency and input voltage have also been demonstrated via manufacturing the micro-dimple arrays and two-tier microstructured surfaces. High-precision microstructures were obtained with 1.26% and 10.67% machining errors in wavelength and height, respectively.

Development of a two-frequency, elliptical-vibration texturing device for surface texturing

2017 ◽  
Vol 31 (7) ◽  
pp. 3465-3473 ◽  
Author(s):  
Rendi Kurniawan ◽  
Tae Jo Ko ◽  
Li Chang Ping ◽  
S. Thirumalai Kumaran ◽  
Gandjar Kiswanto ◽  
...  
Keyword(s):  
Surface Texturing ◽  
Elliptical Vibration ◽  
Elliptical Vibration Texturing

Development of a New Vibrator for Elliptical Vibration Texturing

2011 ◽  
Author(s):  
Ping Guo ◽  
Kornel F. Ehmann
Keyword(s):  
Resonant Mode ◽  
Experimental Result ◽  
Design Parameters ◽  
Vibration Modes ◽  
Turning Process ◽  
Vibration Cutting ◽  
Elliptical Vibration ◽  
Preliminary Experimental Result ◽  
Elliptical Vibration Texturing ◽  
Cutting Direction

Inspired by the idea of vibro-mechanical texturing, which adds a tertiary motion to the tool tip in the conventional turning process, and the elliptical vibration cutting process, which adds vibrations both in the cutting direction and feed direction, this paper proposes a new design for an ultrasonic vibrator for the elliptical vibration texturing process. The elliptical locus lies in the plane that is defined by the cutting and the radial directions. The device could be easily adapted for elliptical cutting applications by changing the orientation of the tool tip. The vibrator works in the resonant mode, with in-phase and anti-phase vibration modes at a nearly identical natural frequency. Simulations and experiments have been carried out to study and verify different vibration modes of the system. Different design parameters have been analyzed to control the elliptical trajectory of the tool tip. A set of preliminary experimental result of elliptical vibration texturing is also provided.

Modeling the Force, Surface Roughness and Cutting Temperature in Ultrasonic Vibration-Assisted Turning of Al7075

2009 ◽  
Vol 83-86 ◽  
pp. 315-325 ◽  
Author(s):  
Mohammad Javad Nategh ◽  
Saeed Amini ◽  
H. Soleimanimehr
Keyword(s):  
Surface Roughness ◽  
Ultrasonic Vibration ◽  
Single Point ◽  
Cutting Temperature ◽  
Depth Of Cut ◽  
Ultrasonic Frequency ◽  
Factorial Experiments ◽  
Machining Force ◽  
Cutting Velocity ◽  
Full Factorial

The single point cutting tool in ultrasonic vibration-assisted turning (UAT) is made to vibrate under ultrasonic frequency. In present study, the influence of various parameters such as vibration amplitude, depth of cut, feed rate and cutting velocity on the machining force and workpiece's surface roughness in UAT of Al7075 has been investigated. Full factorial experiments were carried out with an ultrasonic frequency range of 20±0.5 kHz. ANOVA was conducted on the experimental results and regression models were obtained for predicting the machining force, surface roughness and cutting temperature. The proposed models were verified by further experiments. The robustness of the proposed models was then investigated whence the optimal parameters were estimated. Similar full factorial experiments were also carried out with conventional turning (CT) in order to compare the results with those of UAT.

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