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.

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.

The effect of monolayer TiCN-, AlTiN-, TiAlN-and two layers TiCN + TiN- and AlTiN + TiN-coated cutting tools on tool wear, cutting force, surface roughness and chip morphology during high-speed milling of Ti6Al4V titanium alloy

2016 ◽  
Vol 232 (7) ◽  
pp. 1273-1286 ◽  
Author(s):  
Emel Kuram
Keyword(s):  
Surface Roughness ◽  
Titanium Alloy ◽  
Tool Wear ◽  
Cutting Force ◽  
High Speed ◽  
Cutting Tools ◽  
Chip Morphology ◽  
High Speed Milling ◽  
Ti6al4v Titanium Alloy ◽  
Coated Carbide

Tool coatings can improve the machinability performance of difficult-to-cut materials such as titanium alloys. Therefore, in the current work, high-speed milling of Ti6Al4V titanium alloy was carried out to determine the performance of various coated cutting tools. Five types of coated carbide inserts – monolayer TiCN, AlTiN, TiAlN and two layers TiCN + TiN and AlTiN + TiN, which were deposited by physical vapour deposition – were employed in the experiments. Tool wear, cutting force, surface roughness and chip morphology were evaluated and compared for different coated tools. To understand the tool wear modes and mechanisms, detailed scanning electron microscope analysis combined with energy dispersive X-ray of the worn inserts were conducted. Abrasion, adhesion, chipping and mechanical crack on flank face and coating delamination, adhesion and crater wear on rake face were observed during high-speed milling of Ti6Al4V titanium alloy. In terms of tool wear, the lowest value was obtained with TiCN-coated insert. It was also found that at the beginning of the machining pass TiAlN-coated insert and at the end of machining TiCN-coated insert gave the lowest cutting force and surface roughness values. No change in chip morphology was observed with different coated inserts.

scholarly journals Rotary ultrasonic machining of SiCp/Al composites: An experimental study on cutting force and machinability

2019 ◽  
Vol 11 (12) ◽  
pp. 168781401989832
Author(s):  
Ming Wang ◽  
Wei Zheng ◽  
Ming Zhou ◽  
Qun Zhang
Keyword(s):  
Experimental Study ◽  
Cutting Force ◽  
Volume Fraction ◽  
High Volume ◽  
Processing Parameters ◽  
Grinding Force ◽  
Ultrasonic Machining ◽  
Processing Quality ◽  
Rotary Ultrasonic Machining ◽  
The Cost

To improve the processing quality and reduce the cost of SiCp/Al composites has become a key problem for its application. Rotary ultrasonic machining is highly suitable for machining of SiCp/Al composites with a medium or high volume fraction of reinforced phase, and the processing quality and efficiency could be improved greatly. In this article, the rotary ultrasonic machining experiments were performed for the SiCp/Al composites reinforced with 45% volume fraction, and the effects of processing parameters on the cutting force of face and flank machining were studied. The cutting force values reduce significantly, and the grinding force ratios Fn/ Ft of face and flank machining are 2.843 and 1.336, respectively, which indicate that better machinability can be achieved for SiCp/Al composites using rotary ultrasonic machining.

Research on Wear Mechanisms while Turning Titanium Alloy TC4

2010 ◽  
Vol 97-101 ◽  
pp. 1845-1848
Author(s):  
Dong Liu ◽  
Wu Yi Chen ◽  
Hong Hai Xu ◽  
Xue Ke Luo
Keyword(s):  
Titanium Alloy ◽  
Tool Wear ◽  
Cutting Force ◽  
Flank Wear ◽  
Aerospace Industry ◽  
Cutting Temperature ◽  
High Chemical ◽  
Adhesion Wear ◽  
Wear Tool ◽  
High Chemical Activity

Titanium alloys are widely used in aerospace industry due to their excellent mechanical properties. Because of their low thermal conductivity, high chemical activity, large friction coefficient and so on, such problems occur during the cutting process as high cutting temperature, large specific cutting force and serious tool wear, leading to low machining efficiency. The cutting force, forms of tool wear; wear mechanics were experimentally studied and analyzed while machining titanium alloy TC4 using carbide tools YS8 and YG8. The experimental results indicated that the tool wear of YG8 influenced cutting force not very remarkable when flank wear smaller than 0.25mm. But when the flank wear was bigger than 0.25mm, the cutting force increased rapidly with the flank wear increased. And the tool wear influenced the cutting force dramatically. The forms of tool wear during machining TC4 using carbide tool were adhesion wear, tool chipping and. The desquamation and chipping of tool caused by adhesion wear were the main reason of the tool failure.

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.

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.

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