Experimental Investigation Into Rotary Ultrasonic Machining of Alumina

2004 ◽  
Author(s):  
W. M. Zeng ◽  
Z. C. Li ◽  
N. J. Churi ◽  
Z. J. Pei ◽  
C. Treadwell
Keyword(s):  
Surface Roughness ◽  
Cutting Force ◽  
Feed Rate ◽  
Rotational Speed ◽  
Experimental Studies ◽  
Ultrasonic Power ◽  
Ultrasonic Machining ◽  
Rotary Ultrasonic Machining ◽  
Control Variables ◽  
Diamond Drilling

Many experimental studies have been conducted to explore the relations between control variables and process outputs in rotary ultrasonic machining (RUM). However, there are few reports on the comparison between RUM and conventional diamond drilling. In this paper, the cutting force and surface roughness are compared when machining alumina with RUM method and with conventional diamond drilling method. Furthermore, the effects of the control variables (rotational speed, feed rate, and ultrasonic power) on RUM outputs (such as cutting force and surface roughness) are studied. It is found that in comparison with conventional diamond drilling, the cutting force can be reduced significantly and the surface roughness can be improved by using RUM. It is also found that rotational speed, feed rate, and ultrasonic power have significant effects on RUM process.

Rotary Ultrasonic Machining of Basalt Rock Using Compressed Air As Coolant: A Study on Edge Chipping and Surface Roughness

2019 ◽  
Author(s):  
Palamandadige Fernando ◽  
Meng Zhang ◽  
Zhijian Pei ◽  
Adam Owens
Keyword(s):  
Surface Roughness ◽  
Cutting Force ◽  
Construction Material ◽  
Compressed Air ◽  
Ultrasonic Power ◽  
Ultrasonic Machining ◽  
Rotary Ultrasonic Machining ◽  
Machining Processes ◽  
Edge Chipping ◽  
Basalt Rock

Abstract The aim of this study is to investigate the edge chipping and surface roughness of basalt rock processed by rotary ultrasonic machining (RUM) using compressed air as coolant. Basalt rock is commonly used as a building and construction material for foundations and dams, as well as in architectural designs such as constructing thin veneers and facades. Rotary ultrasonic machining, a hybrid process of grinding and ultrasonic machining, is employed to drill difficult-to-machine materials such as ceramics, composites, titanium alloys, stainless steel, etc. RUM has many advantages over conventional machining processes such as twist drilling. These advantages include lower cutting force, higher surface quality, lower tool wear, etc. This paper is the first in literature to report a study on edge chipping and surface roughness on RUM of basalt rock using cold compressed air as coolant. The effects of three input variables (tool rotation speed, feedrate, and ultrasonic power) on cutting force, torque, edge chipping, and surface roughness were studied. Experimental results obtained from this investigation show that RUM with cold air as the coolant has the capability to machine holes in basalt rock with a surface roughness of less than 3.5 μm without severe edge chipping.

Comparison of Superabrasive Tools in Rotary Ultrasonic Machining of Stainless Steel

2010 ◽  
Author(s):  
Weilong Cong ◽  
Qiang Feng ◽  
Z. J. Pei ◽  
Clyde Treadwell
Keyword(s):  
Surface Roughness ◽  
Stainless Steel ◽  
Cutting Force ◽  
Ultrasonic Power ◽  
Ultrasonic Machining ◽  
Rotary Ultrasonic Machining ◽  
Time In Literature ◽  
Reported Study ◽  
Input Variables ◽  
Superabrasive Materials

Many experiments on rotary ultrasonic machining (RUM) have been conducted to study how input variables (including tool rotation speed, ultrasonic power, feedrate, and abrasive size) affect output variables (such as cutting force, torque, surface roughness, and edge chipping) by using diamond tools. However, a literature review has revealed that there is no reported study on CBN tools in RUM. This paper, for the first time in literature, presents an investigation of RUM of stainless steel using CBN tools. Firstly, an introduction of superabrasive materials and RUM principle was provided. After presenting the experiment procedures and workpiece properties, it reports the results on tool wear, cutting force, torque, surface roughness in RUM of stainless. Finally, it discusses and compares the performances of diamond and CBN tools in RUM of stainless steel under certain conditions.

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.

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.

Influence of Machining Parameters on Surface Topography of Cubic Boron Nitride at Rotary Ultrasonic Machining

2016 ◽  
Vol 686 ◽  
pp. 180-185 ◽  
Author(s):  
Marcel Kuruc ◽  
Martin Kusý ◽  
Vladimír Šimna ◽  
Jozef Peterka
Keyword(s):  
Surface Roughness ◽  
Boron Nitride ◽  
Feed Rate ◽  
Cubic Boron Nitride ◽  
Cutting Speed ◽  
Machining Parameters ◽  
Ultrasonic Machining ◽  
Rotary Ultrasonic Machining ◽  
Hard And Brittle Materials ◽  
Advanced Machining

Poly-crystalline cubic boron nitride (PCBN) is one of the hardest known material. Therefore only advanced methods are able to treat such material. Advanced machining methods, proper for machining of hard and brittle materials (such as glass and ceramics) include rotary ultrasonic machining (RUM). This method should achieve high precision and low surface roughness (at least during machining of materials such as ceramics). Achievable roughness is affected by machined material and machining parameters. This contribution investigates influence of machining parameters, such as cutting speed and feed rate, on resultant surface roughness during machining of PCBN by rotary ultrasonic machining.

Empirical study on ultrasonic assisted turn-milling

2021 ◽  
pp. 095440892110087
Author(s):  
Saeid Amini ◽  
Mohammad Baraheni ◽  
Mohammad Khaki
Keyword(s):  
Surface Roughness ◽  
Cutting Force ◽  
Ultrasonic Vibration ◽  
Feed Rate ◽  
Rotational Speed ◽  
Milling Process ◽  
Machining Process ◽  
Machining Parameters ◽  
Machining Processes ◽  
Turn Milling

Turn-milling process has been paid attention in order to be used in multi-task machining processes. Moreover, looking for new machining techniques aimed at reducing cutting force is of important. Reducing cutting force in machining processes has the benefits of extending tool life and improving surface quality. One of the new concepts for reducing the cutting force is applying ultrasonic vibration. In this paper, effects of ultrasonic vibration under different machining parameters in turn-milling process of Al-7075 alloy will be investigated. In this order, a special mechanism was designed to apply ultrasonic vibration during machining process. Ultrasonic vibration exertion on the tool reduced cutting force and surface roughness up to 75% and 35%, respectively. Also tool rotational speed increment induced cutting force and surface roughness increment. In addition, tool feed rate and workpiece rotational speed increment caused cutting force and surface roughness increment. Although, feed rate was more influential.

Rotary Ultrasonic Machining of Titanium Alloy: A Feasibility Study

2005 ◽  
Author(s):  
N. J. Churi ◽  
Z. C. Li ◽  
Z. J. Pei ◽  
C. Treadwell
Keyword(s):  
Experimental Study ◽  
Surface Roughness ◽  
Titanium Alloy ◽  
Tool Wear ◽  
Titanium Alloys ◽  
Cutting Force ◽  
Aerospace Industry ◽  
Ultrasonic Machining ◽  
Rotary Ultrasonic Machining ◽  
Conventional Machining

Due to their unique properties, titanium alloys are attractive for some unique applications especially in the aerospace industry. However, it is very difficult to machine these materials cost-effectively. Although many conventional and non-conventional machining methods have been reported for machining them, no reports can be found in the literature on rotary ultrasonic machining of titanium alloys. This paper presents an experimental study on rotary ultrasonic machining of a titanium alloy. The tool wear, cutting force, and surface roughness when rotary ultrasonic machining of the titanium alloy have been investigated using different tool designs and machining conditions. The results are compared with those when machining the same material with diamond grinding.

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