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.

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.

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.

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.

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 CFRP: Effects of Abrasive Properties

2018 ◽  
Author(s):  
Palamandadige Fernando ◽  
Meng Zhang ◽  
Zhijian Pei
Keyword(s):  
Surface Roughness ◽  
Cutting Force ◽  
Machining Process ◽  
Ultrasonic Machining ◽  
Rotary Ultrasonic Machining ◽  
Machining Processes ◽  
Reinforced Plastics ◽  
Abrasive Properties ◽  
Hole Making ◽  
Abrasive Size

Drilling is the most common machining practice conducted on carbon fiber reinforced plastics (CFRP), which is challenging to conventional machining processes, such as twist drilling. Rotary ultrasonic machining (RUM) is a non-traditional machining process that has been successfully used to drill CFRP, many other brittle (e.g. silicon, ceramics), and ductile (e.g. titanium alloy (Ti-6Al-4V), stainless steel) materials. RUM is superior to twist drilling on CFRP hole-making in many aspects: lower cutting force and torque, better surface finish, less potential for delamination, and better tool life. Since RUM is a hybrid process of abrasive grinding and ultrasonic machining, it is important to study the effects of abrasive properties on output variables. This paper for the first time investigates the effects of abrasive properties (abrasive size and abrasive concentration) on output variables (cutting force, torque, and surface roughness) in RUM of CFRP. It is found that cutting force increased as abrasive size increased and as abrasive concentration increased; however, abrasive properties did not have significant effects on surface roughness of the machined holes.

Feasibility Study of Longitudinal–Torsional-Coupled Rotary Ultrasonic Machining of Brittle Material

2018 ◽  
Vol 140 (5) ◽  
Author(s):  
Jianjian Wang ◽  
Jianfu Zhang ◽  
Pingfa Feng ◽  
Ping Guo ◽  
Qiaoli Zhang
Keyword(s):  
Surface Roughness ◽  
Cutting Force ◽  
Brittle Material ◽  
Cutting Speed ◽  
Spindle Speed ◽  
Ultrasonic Machining ◽  
Rotary Ultrasonic Machining ◽  
Workpiece Material ◽  
Edge Chipping

In order to further improve the processing performance of rotary ultrasonic machining (RUM), a novel longitudinal–torsional-coupled (LTC) vibration was applied to the RUM. An experimental study on quartz glass was performed to access the feasibility of the LTC-RUM of a brittle material. The LTC-RUM was executed through the addition of helical flutes on the tool of conventional longitudinal RUM (Con-RUM). The experimental results demonstrated that the LTC-RUM could reduce the cutting force by 55% and the edge chipping size at the hole exit by 45% on an average, compared to the Con-RUM. Moreover, the LTC-RUM could also improve the quality of the hole wall through the reduction of surface roughness, in particular, when the spindle speed was relatively low. The mechanism of superior processing performance of LTC-RUM involved the corresponding specific moving trajectory of diamond abrasives, along with higher lengths of lateral cracks produced during the abrasives indentation on the workpiece material. The higher edge chipping size at the hole entrance of LTC-RUM indicated a higher length of lateral cracks in LTC-RUM, due to the increase in the maximum cutting speed. Furthermore, the effect of spindle speed on the cutting force and surface roughness variations verified the important role of the moving trajectory of the diamond abrasive in the superior processing performance mechanism of LTC-RUM.

Experimental study on rotary ultrasonic machining of alumina ceramic: Microstructure analysis and multi-response optimization

2016 ◽  
Vol 232 (12) ◽  
pp. 967-986 ◽  
Author(s):  
Ravi Pratap Singh ◽  
Sandeep Singhal
Keyword(s):  
Surface Roughness ◽  
Industrial Applications ◽  
Alumina Ceramic ◽  
Ultrasonic Power ◽  
Ultrasonic Machining ◽  
Rotary Ultrasonic Machining ◽  
Desirability Approach ◽  
Response Optimization ◽  
Ceramic Microstructure ◽  
Experimental Values

Excellent and superior properties of alumina ceramic make it a one of the highly demanded advanced ceramics in the present competitive scenario of manufacturing and industrial applications. However, its effective and economic processing is still a challenge. The present article has targeted to experimentally investigate the influence of several process variables, namely spindle speed, feed rate, coolant pressure, and ultrasonic power on different machining performances, i.e. surface roughness, and chipping thickness. Response surface methodology has been employed to design the experiments. Microstructure of the machined samples has been evaluated and analyzed through scanning electron microscope. This analysis has revealed and confirmed the presence of plastic deformation of work surface that caused the material removal along with the dominated brittle fracture in the processing of alumina ceramic with rotary ultrasonic machining. The multi-response optimization of machining responses has been done by using desirability approach. At the optimized parametric setting, the obtained experimental values for surface roughness and chipping thickness are found to be 0.215 µm and 0.159 mm, respectively.

Sign in / Sign up

Export Citation Format

Share Document