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.

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.

A novel three-dimensional elliptical vibration cutting device based on the freedom and constraint topologies theory

2018 ◽  
Vol 233 (3) ◽  
pp. 675-685 ◽  
Author(s):  
Sheng Lin ◽  
Xi Kong ◽  
Chun Wang ◽  
Yun Zhai ◽  
Liang Yang
Keyword(s):  
Design Theory ◽  
Compliant Mechanism ◽  
Three Dimensional ◽  
Cutting Speed ◽  
Elliptical Vibration Cutting ◽  
Vibration Cutting ◽  
Elliptical Vibration ◽  
The Common ◽  
Constraint Topologies ◽  
The Relationship

Aiming at the issue of the lack of the design theory for the three-dimensional elliptical vibration cutting device, a compliant mechanism with two rotations and one translation is synthesized based on the theory of freedom and constraint topologies. And a three-dimensional elliptical vibration cutting device is proposed on the basis of the compliant mechanism. The relationship between the critical speed and the length of the tool bar is analyzed. Simulation is conducted to analyze the influence of parameters on the output ellipse. Experiments are conducted to verify the validity of the elliptical vibration cutting device. The relationship between the roughness and the cutting speed is obtained. Experiments with different driving frequencies are conducted without the change of other parameters. Results show that the proposed compliant mechanism is feasible for the elliptical vibration cutting device. Compared with the common cutting, the new elliptical vibration cutting device has a better performance in the processing effect. This provides an important reference for design of the elliptical vibration cutting device.

scholarly journals Deformation Structures and Tool Wear during High-Speed Machining

2013 ◽  
Vol 10 (1) ◽  
pp. 12-17
Author(s):  
Karol Vasilko
Keyword(s):  
High Speed ◽  
Cutting Speed ◽  
Tool Material ◽  
Machining Process ◽  
Surface Dynamics ◽  
Machined Surface ◽  
Deformation Structures ◽  
Cutting Speeds ◽  
Tool Durability

Abstract Tendencies towards increasing cutting speeds during machining can be observed recently. The first wave of increasing cutting speeds occured in the 60s of the previous century. However, suitable tool material was not available at that time. Increasing cutting speed is possible only following the development of cutting material, resistant against high temperatures, abrasive, adhesive and diffusive wear. It is obvious that the process of chip creation, quality of machined surface, dynamics of machining process and temperature of cutting change considerably with cutting speed. To be able to apply higher cutting speeds in production machining, it is necessary to know the dependence of those characteristics on cutting speed. Some of those phenomena, which are linked with cutting speed, will be explained in the paper. Key words: machining, cutting speed, tool durability, surface quality

Performance Evaluation of TiAlN-PVD Coated Inserts for Machining Ti-6Al-4V under Different Cooling Strategies

2013 ◽  
Vol 685 ◽  
pp. 68-75 ◽  
Author(s):  
Salman Pervaiz ◽  
Ibrahim Deiab ◽  
Basil Darras ◽  
Amir Rashid ◽  
Mihai Nicolescu
Keyword(s):  
Flank Wear ◽  
Cutting Speed ◽  
Cutting Edge ◽  
Machined Surface ◽  
Cutting Inserts ◽  
Low Levels ◽  
Coated Carbide ◽  
Cutting Experiments ◽  
Cutting Speeds ◽  
Scanning Electron

Titanium alloys are labeled as difficult to materials because of their low machinability rating. This paper presents an experimental study of machining Ti-6Al-4V under turning operation. All machining tests were conducted under dry, mist and flood cooling approaches by using a TiAlN coated carbide cutting inserts. All cutting experiments were conducted using high and low levels of cutting speeds and feed rates. The study compared surface finish of machined surface and flank wear at cutting edge under dry, mist and flood cooling approaches. Scanning electron microscopy was utilized to investigate the flank wear at cutting edge under various cooling approaches and cutting conditions. Investigation revealed that TiAlN coated carbides performed comparatively better at higher cutting speed.

Study of Cutting Speed Variation in the Ultrasonic Assisted Drilling of Carbon Fibre Composites

2014 ◽  
Author(s):  
Aniruddha Gupta ◽  
Stuart Barnes ◽  
Iain McEwen ◽  
Nadia Kourra ◽  
Mark A. Williams
Keyword(s):  
Cutting Temperature ◽  
Cutting Speed ◽  
Hole Drilling ◽  
Machining Parameters ◽  
Machined Surface ◽  
Internal Damage ◽  
Significant Difference ◽  
Ultrasonic Assisted ◽  
Carbon Fibre Composites ◽  
Cutting Speeds

Ultrasonic assisted drilling (UAD) has been proven effective for the thrust force reduction as compared to conventional drilling (CD) for same machining parameters. The following research was focused on the examination of exit delamination, machined surface and cutting temperature measurement in UAD and a comparison to that in CD at the cutting speeds of 0.942 m/min, 9.42 m/min, 94.2 m/min and 282.6 m/min at a constant feed rate of 0.05 mm/rev in the through-hole drilling of CFRP material. X-Ray computed tomography (CT) was used to identify the exit delamination, internal damage, circularity and center deviation in CD and UAD. A maximum of 82.8% reduction in the center deviation and 33.2% reduction in circularity of the holes were found when drilled in UAD as compared to those in CD. Furthermore, the cutting temperature in the drilling of CFRP has been measured and compared for both the cases of CD and UAD. Ultrasonic assistance produced 10°C higher cutting temperature than that in CD at the cutting speed of 282.6 m/min while at lower cutting speeds (0.942 m/min and 9.42 m/min), the cutting temperatures with and without ultrasonic assistance did not have a significant difference (2°C and 4°C respectively).

Built-Up-Edge Formation in Micromilling

2015 ◽  
Author(s):  
V. Kovvuri ◽  
Z. Wang ◽  
A. Araujo ◽  
M. B. da Silva ◽  
S. Bukkapatnam ◽  
...  
Keyword(s):  
Surface Finish ◽  
Cutting Speed ◽  
Minimum Quantity Lubrication ◽  
Cutting Parameters ◽  
Tool Geometry ◽  
Machined Surface ◽  
Area Density ◽  
Milled Surface ◽  
Chip Load ◽  
Cutting Speeds

This paper presents experimental study on conditions for built-up-edge (BUE) formation and its effects in micromilling. Surface finish and BUE area density on a micromilled surface are used to quantify the presence of BUE. A model for surface finish is derived based on the topography of milled surface and tool geometry. Assuming no BUE formation, this empirical model shows the dependence of surface finish on chip load, tool concavity angle, and includes the effect of cutting parameters and milling modes (up-milling or down-milling). Micromilling tools of 100–400 μm diameters are used for milling stainless steel at 10–60 m/min cutting speed, 0.05–1 μm/flute chip load, in minimum quality lubrication condition (MQL). A BUE, embedded onto either a milled surface or tool cutting edge or chip, is identified by scanning electron microscopy and energy dispersive spectroscopy techniques; the severity of BUE formation is quantified as area density when observing a machined surface at high magnification with optical microscopy or interferometry. Condition for BUE formation is presented by mapping the surface finish and BUE area density against cutting speed and chip load. A microtool would fracture catastrophically at high cutting speeds and/or high chip loads due to excessive dynamic stresses on a microtool; such tool would also fail at the other extreme when low cutting speeds and chip loads promote formation and detachment of BUE on the tool surface, therefore, chipping the fragile microcutting edges of a microtool. There is an optimal zone for effective micromilling without tool failure and BUEs. The measured surface finish approaches the theoretical value when BUE is absent, i.e. micromilling in minimum quantity lubrication at cutting speed between 40–60 m/min and chip load higher than 0.15μm/tooth. The BUE area density for up-milling is lower than that for down-milling at low cutting speed; such difference gradually diminishes when selecting milling parameters in the optimal zone where BUE is practically absent.

Experimental Study of Cutting Forces in Micro End-Milling

2012 ◽  
Vol 500 ◽  
pp. 357-362 ◽  
Author(s):  
Xiu Bing Jing ◽  
Huai Zhong Li ◽  
Jun Wang ◽  
Jong Leng Liow
Keyword(s):  
Experimental Study ◽  
Feed Rate ◽  
Cutting Forces ◽  
End Milling ◽  
Cutting Speed ◽  
Micro Milling ◽  
Planning And Control ◽  
Micro End Milling ◽  
And Control ◽  
Cutting Speeds

Micro-end-milling is an efficient and economical manufacturing operation that is capable of accurately producing high aspect ratio features and parts. It is important to study the cutting forces in micro-milling for the planning and control of the process. This paper presents an experimental study of the cutting forces in micro-end-milling of a 6160 aluminum alloy. The measured cutting forces are presented and discussed for different cutting conditions, such as various feeds per tooth, cutter diameters, and cutting speeds. It is found that the peak cutting forces increase with increasing cutting speed and feed rate. The effects of tool runout on the cutting forces were also analyzed based on the experimental results, from which the influences of feed rate and cutting speed are found to be obvious.

A Study on Surface Generation along Nominal Cutting Direction in Elliptical Vibration Cutting

2011 ◽  
Vol 314-316 ◽  
pp. 1851-1856 ◽  
Author(s):  
Xin Quan Zhang ◽  
A. Senthil Kumar ◽  
Mustafizur Rahman
Keyword(s):  
Cutting Speed ◽  
Surface Generation ◽  
Machining Parameters ◽  
Generation Process ◽  
Promising Technique ◽  
Machined Surface ◽  
Elliptical Vibration Cutting ◽  
Vibration Cutting ◽  
Elliptical Vibration ◽  
Cutting Direction

The elliptical vibration cutting (EVC) technique has been found to be a promising technique for ultraprecision machining of various materials. Researchers have proved that the EVC technique prevails over both conventional cutting and 1D vibration cutting techniques in most aspects in terms of cutting performances. However, during the EVC process, vibration marks or cusps are generated by the elliptical vibration locus and can result in an increase in the overall roughness of machined surface, which is undesirable for achieving high-quality mirror surface. Although researchers have developed a calculation method for the height of the cusps, only the effects of vibration frequency on surface generation were studied, and the effects of the other vibration and machining parameters have not been investigated in detail by previous researchers. Hence, in the present study, in order to deeply understand surface generation process along nominal cutting direction under the EVC technique, which is critical for its performance improvement and application, an experimental study comprising a series of grooving tests was carried out. The effects of nominal cutting speed on the surface generation at two different thrust-directional vibration amplitudes are investigated. Analysis is given for the comparison between the theoretical and experimental roughness values, showing that there exists a critical nominal cutting speed, below which the measured roughness value is quite small and the vibration marks are almost undetectable.

scholarly journals Metallurgical and Machinability Characteristics of Wrought and Selective Laser Melted Ti-6Al-4V

2016 ◽  
Vol 2016 ◽  
pp. 1-10 ◽  
Author(s):  
Manikandakumar Shunmugavel ◽  
Ashwin Polishetty ◽  
Junior Nomani ◽  
Moshe Goldberg ◽  
Guy Littlefair
Keyword(s):  
Tool Wear ◽  
Cutting Tool ◽  
Flank Wear ◽  
Research Work ◽  
Cutting Speed ◽  
Machined Surface ◽  
Machined Surface Quality ◽  
Coating Delamination ◽  
All Speeds ◽  
Cutting Speeds

This research work presents a machinability study between wrought grade titanium and selective laser melted (SLM) titanium Ti-6Al-4V in a face turning operation, machined at cutting speeds between 60 and 180 m/min. Machinability characteristics such as tool wear, cutting forces, and machined surface quality were investigated. Coating delamination, adhesion, abrasion, attrition, and chipping wear mechanisms were dominant during machining of SLM Ti-6Al-4V. Maximum flank wear was found higher in machining SLM Ti-6Al-4V compared to wrought Ti-6Al-4V at all speeds. It was also found that high machining speeds lead to catastrophic failure of the cutting tool during machining of SLM Ti-6Al-4V. Cutting force was higher in machining SLM Ti-6Al-4V as compared to wrought Ti-6Al-4V for all cutting speeds due to its higher strength and hardness. Surface finish improved with the cutting speed despite the high tool wear observed at high machining speeds. Overall, machinability of SLM Ti-6Al-4V was found poor as compared to the wrought alloy.

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