Improving Productivity in an Ultrasonic-Assisted Drilling Vertical Machining Center

2018 ◽  
Vol 140 (6) ◽  
Author(s):  
M. A. Moghaddas ◽  
M. A. Short ◽  
N. R. Wiley ◽  
A. Y. Yi ◽  
K. F. Graff
Keyword(s):  
Ultrasonic Vibrations ◽  
Machining Processes ◽  
Machining Center ◽  
Ultrasonic Drilling ◽  
Standard Tool ◽  
Ultrasonic Assisted ◽  
Ultrasonic Assisted Machining ◽  
Conventional Machine ◽  
Solid Foundation ◽  
Sufficient Strength

Ultrasonic-assisted machining, which is the application of ultrasonic vibrations to standard or “conventional” machine tools for processes such as drilling, milling, and turning, is a rapidly developing technology aimed at increasing the productivity of machining processes. While a solid foundation is being established through laboratory-based research studies, typically these processes have not yet progressed to fulfill the demanding requirements of the factory floor. The objective of the current work is to transition the ultrasonic-assisted drilling (UAD) process from the laboratory to a production system compatible with automated machining systems. This work details the design and development of an ultrasonic drilling module that has sufficient strength, stiffness, and accuracy for production demands, while maintaining powerful levels of ultrasonic vibrations that result in lowered drilling forces and faster feed rates. In addition, this work will review prior work in UAD, including the development of a module based on a vibration-isolating case using a standard tool holder. Performance of the system is shown to provide thrust force reductions, while maintaining or improving surface finish and drilling accuracy. The results from drilling several materials are presented.

scholarly journals Effects of coolant flow rate under ultrasonic vibrations transmitted to surface roughness in grinding SKD11 steel

2017 ◽  
Vol 20 (K6) ◽  
pp. 60-65
Author(s):  
Dong Tien Nguyen ◽  
Trung Van Tran
Keyword(s):  
Surface Roughness ◽  
Flow Rate ◽  
Coolant Flow ◽  
Coolant Flow Rate ◽  
Grinding Wheel ◽  
Ultrasonic Vibrations ◽  
Machining Processes ◽  
Ultrasonic Assisted ◽  
Ultrasonic Assisted Machining ◽  
The Impact

The ultrasonic assisted machining method is now widely applied and supported in machining processes such as drilling, turning, milling and especially grinding. This paper presents the effect of coolant flow rate q (3.5, 4.5 and 5 l.min-1 respectively) under ultrasonic vibrations transmitted in grinding SKD11 steel. The surface roughness Ra was used to evaluate the impact. The results show that, when no ultrasonic vibrations were transmitted, the surface roughness values are approximately equivalent when changing the coolant flow rate. However, when transmitting the ultrasonic oscillator to the coolant, the coolant flow rate increases, the effect of ultrasound is clear. The results show that the surface roughness of the workpiece decreases as the coolant flow increases. In other words, the coolant was transmitted by ultrasonic vibrations that clean the grinding wheel surface, removing the grinding chips that stick to the space between the abrasives grains, ensuring the grindability of grinding wheels.

Ultrasonic Assisted Machining for Hard-to-Cut Materials

2015 ◽  
Vol 809-810 ◽  
pp. 345-350
Author(s):  
Elena Adina Cotargă ◽  
Marcel Sabin Popa ◽  
Stefan Sattel ◽  
Dan Preja ◽  
Ovidiu Virgil Vereș ◽  
...  
Keyword(s):  
Large Scale ◽  
Advanced Materials ◽  
Current Status ◽  
Ultrasonic Machining ◽  
Machining Processes ◽  
Reinforced Plastics ◽  
Ultrasonic Drilling ◽  
Ultrasonic Assisted ◽  
Ultrasonic Assisted Machining ◽  
Tool Company

This study presents new machining types of advanced materials. Super alloys, ceramics and fiber reinforced plastics started being used on a large scale in the last period, this making necessary the development of new machines and machining processes. This paper describes different methods of ultrasonic machining and makes a comparison between them. By ultrasonic machining can be understood a process that involves axial vibrations with a high frequency and low amplitude, for improving the machining conditions like chip flute removal, tool wear and temperature reducing. In this paper, are presented three different ultrasonic machining methods. In the first one, the cutting process is made by abrasive slurry inserted between the tool and the workpiece, in the second one is made by a rotating diamond-brazed tool and in the last one is made by a special drill. This paper aims to study the current status in this field in order to make a research program through collaboration between the Technical University of Cluj-Napoca and the tool company Gühring KG by which to develop ultrasonic drilling.

The Development of an Ultrasonic Head for CMP Pad Conditioning

2012 ◽  
Vol 500 ◽  
pp. 275-280
Author(s):  
Pei Lum Tso ◽  
Shi Guo Liu ◽  
J. C. Wang
Keyword(s):  
Chemical Mechanical Polishing ◽  
Mechanical Polishing ◽  
Machining Processes ◽  
Conditioning Process ◽  
Polishing Pad ◽  
Key Word ◽  
Ultrasonic Assisted ◽  
Ultrasonic Assisted Machining ◽  
Pad Conditioning ◽  
The Cost

The technology of ultrasonic assisted machining has been successfully used in many machining processes recently. Conditioning in the CMP not only can extending the life of the polishing pad but also improve process stability. In this paper we develop a brand new conditioning process with ultrasonic assisted conditioning UAC head for chemical mechanical polishing CMP process. The slurry came from inside the polishing spindle and had an independent cyclic system. As a result, this UAC device can remove polishing debris 4-6 times faster than conventional conditioning process. This conditioning process may even use water instead of slurry to reduce the cost of consumables of CMP. Key word: Chemical mechanical polishing CMP, Ultrasonic assisted conditioning UAC, Polishing Pad

Ultrasonic-assisted machining processes: a review

2019 ◽  
Vol 12 (3/4) ◽  
pp. 227
Author(s):  
Girish Chandra Verma ◽  
Pulak Mohan Pandey ◽  
Uday Shanker Dixit
Keyword(s):  
Machining Processes ◽  
Ultrasonic Assisted ◽  
Ultrasonic Assisted Machining

Kinematic Model for Ultrasonic-Assisted Manufacturing of Bore Holes with Undefined Cutting Edges

2011 ◽  
Vol 223 ◽  
pp. 794-803 ◽  
Author(s):  
Uwe Heisel ◽  
Rainer Eber ◽  
Jörg Wallaschek ◽  
Jens Twiefel
Keyword(s):  
Material Removal Rate ◽  
Material Removal ◽  
Removal Rate ◽  
Kinematic Model ◽  
Cutting Speed ◽  
Machining Processes ◽  
Hybrid Machining ◽  
Ultrasonic Assisted ◽  
Ultrasonic Assisted Machining ◽  
Grain Distribution

Hybrid machining represents a possibility for technological progress in production. As a part of hybrid machining processes, ultrasonic-assisted machining is often used to manufacture materials that are difficult to machine since process forces can be significantly reduced and the material removal rate (MRR) can be increased. This paper describes an approach for a model for ultrasonic-assisted drilling with undefined cutting edges. The ultrasonic vibration can theoretically be applied in axial, tangential or radial direction or it can be superimposed. An axial excitation, parallel to the feed direction, is selected in the presented model. Since the drilling is superimposed with a high-frequency vibration, the trajectories of the grains are modified. Therefore, an analytical-kinematic model is established, which is characterised by a periodical contact loss of tool and workpiece. Due to the modified kinematics, process-specific parameters, such as impact velocity or the ratio between vibration and cutting speed, are important, in addition to conventional cutting parameters. Such process parameters are useful to describe dominant material removal mechanisms in ultrasonic-assisted machining. Moreover, two models on tool topography are presented in this paper. Based on an analytical approach, the material removal rate, established by adding up the individual grain removals, is calculated. The quality of the developed models is validated by the standard calculation of the material removal rate by feed rate and tool cross section. The results show, that it must be taken into account that the grains do not hit an even surface. The grain distribution is also an important aspect.

Ultrasonic-assisted machining processes: a review

2019 ◽  
Vol 12 (3/4) ◽  
pp. 227
Author(s):  
Uday Shanker Dixit ◽  
Pulak Mohan Pandey ◽  
Girish Chandra Verma
Keyword(s):  
Machining Processes ◽  
Ultrasonic Assisted ◽  
Ultrasonic Assisted Machining

scholarly journals Ultrasound Effect on the Microstructure and Hardness of AlMg3 Alloy under Upsetting

Materials ◽  
2021 ◽  
Vol 14 (4) ◽  
pp. 1010
Author(s):  
Przemysław Snopiński ◽  
Tibor Donič ◽  
Tomasz Tański ◽  
Krzysztof Matus ◽  
Branislav Hadzima ◽  
...  
Keyword(s):  
Flow Stress ◽  
Ultrasonic Vibration ◽  
Light And Electron Microscopy ◽  
Load Flow ◽  
Forming Limit ◽  
Ultrasonic Vibrations ◽  
Softening Effect ◽  
Simultaneous Application ◽  
Ultrasonic Assisted ◽  
Acoustic Softening

To date, numerous investigations have shown the beneficial effect of ultrasonic vibration-assisted forming technology due to its influence on the forming load, flow stress, friction condition reduction and the increase of the metal forming limit. Although the immediate occurring force and mean stress reduction are known phenomena, the underlying effects of ultrasonic-based material softening remain an object of current research. Therefore, in this article, we investigate the effect of upsetting with and without the ultrasonic vibrations (USV) on the evolution of the microstructure, stress relaxation and hardness of the AlMg3 aluminum alloy. To understand the process physics, after the UAC (ultrasonic assisted compression), the microstructures of the samples were analyzed by light and electron microscopy, including the orientation imaging via electron backscatter diffraction. According to the test result, it is found that ultrasonic vibration can reduce flow stress during the ultrasonic-assisted compression (UAC) process for the investigated aluminum–magnesium alloy due to the acoustic softening effect. By comparing the microstructures of samples compressed with and without simultaneous application of ultrasonic vibrations, the enhanced shear banding and grain rotation were found to be responsible for grain refinement enhancement. The coupled action of the ultrasonic vibrations and plastic deformation decreased the grains of AlMg3 alloy from ~270 μm to ~1.52 μm, which has resulted in a hardness enhancement of UAC processed sample to about 117 HV.

Numerical Simulation of Plunge Force During the Plunge Phase of Friction Stir Welding and Ultrasonic Assisted FSW

2008 ◽  
Author(s):  
Kwanghyun Park ◽  
Bongsuk Kim ◽  
Jun Ni
Keyword(s):  
Numerical Simulation ◽  
Friction Stir Welding ◽  
High Frequency ◽  
Hybrid Welding ◽  
Ultrasonic Vibrations ◽  
Welding Quality ◽  
Friction Stir ◽  
Ultrasonic Assisted ◽  
Welding Force ◽  
Welding Technique

Ultrasonic assisted friction stir welding (UaFSW) is an hybrid welding technique, where high frequency vibration is superimposed on the movement of a rotating tool. The benefit of using ultrasonic vibration in the FSW process refers to the reduction in the welding force and to the better welding quality. The UaFSW system is being developed and its mechanism needs to be understood using both the experiments and the numerical simulations. In this paper, FE simulations of FSW and UaFSW using ABAQUS/Explicit were carried out to examine plunge forces during the plunge phase of FSW and UaFSW, respectively. First, the simulations of the conventional FSW process were validated. Then, simulation of UaFSW process was performed by imposing sinusoidal horizontal ultrasonic vibrations on the tool.

Werkzeuge der ultraschallunterstützten Bearbeitung*/Modelling of an Actorsystem - Development of a tool for ultrasonic assisted machining with an axial-tangential vibration vector

2018 ◽  
Vol 108 (01-02) ◽  
pp. 53-57
Author(s):  
K. Drewle ◽  
T. Stehle ◽  
H: Möhring
Keyword(s):  
Contact Zone ◽  
Brittle Materials ◽  
Wird Eine ◽  
Alternative Method ◽  
Ultrasonic Assisted ◽  
Ultrasonic Assisted Machining ◽  
Hard And Brittle Materials ◽  
Feed Axis

Die schwingungsunterstützte Bearbeitung hat sich bereits bei der Zerspanung von hartspröden Werkstoffen mit einer einachsigen Schwingung in der Kontaktzone bewährt. Untersuchungen zu schwingungsunterstützten Bohrprozessen beschränken sich bisher auf eine Schwingungserzeugung, die entlang der Vorschubachse ausgerichtet ist. Für alternative Schwingungsrichtungen fehlt in erster Linie die geeignete Aktorik. In diesem Beitrag wird eine alternative Methode zur Erzeugung einer axial-tangentialen Schwingung in der Kontaktzone untersucht.   Ultrasonic assisted machining with uniaxial vibration is a well-proven process for machining hard and brittle materials. Existing investigations of vibration assisted drilling and boring processes so far are limited to an oscillation along the feed axis, which primarily due to nonexistent actuators. This contribution will present investigations into an alternative method for creating axial-tangential vibrations in the tool contact zone.

Schwingungsüberlagerte Kreissägewerkzeuge/Ultrasonic-assisted circular sawing

2020 ◽  
Vol 110 (01-02) ◽  
pp. 45-49
Author(s):  
Michael Raab ◽  
Christoph Birenbaum ◽  
Michael Stroka
Keyword(s):  
Cutting Tools ◽  
Cutting Process ◽  
Ultrasonic Vibrations ◽  
Vibration Behavior ◽  
Circular Saw ◽  
Ultrasonic Assisted ◽  
Circular Sawing

Der Beitrag beschreibt einen Ansatz zur simulationsgestützten Nachbildung des Schwingverhaltens dünner scheibenförmiger Werkzeuge bei hochfrequenten Wechselschwingungen. Der Ansatz wurde primär für Kreissägewerkzeuge entwickelt, um diese bereits in der Konzeptphase so zu gestalten, dass diese sich für die ultraschallüberlagerte Zerspanung bei bis zu 20 kHz einsetzen lassen.   This article describes a model which helps to recreate the vibration-behavior of thin circular-shaped cutting tools influenced by ultrasonic vibrations. The model is primarily developed for the conception of circular saw-blades to support the geometric adaption for the ultrasonic-assisted-cutting process (UAC) at 20 kHz.

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