A Study on Ultrasonic Elliptical Vibration Cutting of Hardened Steel Using PCD Tools

2010 ◽  
Author(s):  
Xinquan Zhang ◽  
Chandra Nath ◽  
A. Senthil Kumar ◽  
Mustafizur Rahman ◽  
Kui Liu
Keyword(s):  
Surface Roughness ◽  
Stainless Steel ◽  
Hardened Steel ◽  
Machining Parameters ◽  
Elliptical Vibration Cutting ◽  
Vibration Cutting ◽  
Diamond Tools ◽  
Elliptical Vibration ◽  
Pcd Tools ◽  
Ultrasonic Elliptical Vibration

Ultraprecision machining of hardened steel by the conventional cutting (CC) technique using diamond tools is impossible because of highly chemical affinity between carbon and iron at higher temperature during machining. An intermittently cutting technique, namely, ultrasonic elliptical vibration cutting (UEVC) technique has been being applied for high-quality machining of various difficult-to-cut materials for the last decade. However, study on machining of hardened stainless steel using polycrystalline diamond (PCD) tools applying this cutting technique has not been reported yet. This study presents an experimental study on UEVC of hardened stainless steel (a typical Stavax of 49 HRC) using PCD tools. Face cutting experiments have been carried out to investigate the effects of conventional machining parameters: depth of cut, feed rate, and spindle rotational speed on the performance parameters such as cutting force, tool flank wear, surface roughness and chip formation. A minimum surface roughness Ra value of 10 nm, measured by a stylus profilometer, was achieved. It can be concluded that, while applying UEVC technique, the inexpensive PCD tools compared to the single crystal diamond tools can be effectively applied to obtain optical surface for producing precise dies and molds from hardened steel.

High Frequency Ultrasonic Elliptical Vibration Turning Studty for Weak Rigidity Precision Workpiece

2011 ◽  
Vol 467-469 ◽  
pp. 236-240 ◽  
Author(s):  
Wen Li ◽  
De Yuan Zhang
Keyword(s):  
Surface Roughness ◽  
High Frequency ◽  
Critical Speed ◽  
Machining Efficiency ◽  
Elliptical Vibration Cutting ◽  
Vibration Cutting ◽  
Elliptical Vibration ◽  
Forming Accuracy ◽  
Ultrasonic Elliptical Vibration ◽  
Cutting Direction

Based on analysis of the micro-surface and kinematical formulas of elliptical vibration cutting(EVC), the paper presents that frequency and amplitude of vibration parameter affect surface roughness, forming accuracy and machining efficiency of weak rigidity workpiece: increase vibration frequency are result in lower vibration cutting duty cycle , lower cutting force, advancer critical speed, so advance forming accuracy and machining efficiency; decrease amplitude are result in reduce the height of vibration ripples in cutting direction , so improve surface roughness. Experiences of cutting the weak rigidity workpiece by the designed double bending hybrid vibration high transducer, verified that the high frequency elliptical vibration cutting are proved more conducive to machining weak rigidity workpiece.

Modeling of the Effect of Machining Parameters on Maximum Thickness of Cut in Ultrasonic Elliptical Vibration Cutting

2011 ◽  
Vol 133 (1) ◽  
Author(s):  
Chandra Nath ◽  
Mustafizur Rahman ◽  
Ken Soon Neo
Keyword(s):  
Brittle Materials ◽  
Cutting Speed ◽  
Role Playing ◽  
Machining Parameters ◽  
Elliptical Vibration Cutting ◽  
Tool Vibration ◽  
Vibration Cutting ◽  
Elliptical Vibration ◽  
Hard And Brittle Materials ◽  
Ultrasonic Elliptical Vibration

In recent years, the ultrasonic elliptical vibration cutting (UEVC) technique has been found to be an efficient method for the ultraprecision machining of hard and brittle materials. During the machining at a given nominal depth of cut (DOC), the UEVC technique, because of its inherent mechanism, effectively reduces the thickness of cut (TOC) of the workpiece material through overlapping vibration cycles. For the ductile machining of hard and brittle materials, this TOC plays a critical role. However, the relationships between the nominal DOC, the TOC, and the relevant machining parameters have not yet been studied. In this study, the role playing machining parameters for the TOC are firstly investigated and then theoretical relations are developed for predicting the maximum TOC (TOCm) with respect to the relevant machining parameters. It is found that four machining parameters, namely, workpiece cutting speed, tool vibration frequency, and tangential and thrust directional vibration amplitudes, influence the TOCm. If the speed ratio (ratio of the workpiece cutting speed to the maximum tool vibration speed in the tangential direction) is within a critical value 0.12837, then a reduced TOCm can be obtained. It is also realized that if the TOCm can be kept lower than the critical DOC (DOCcr), then ductile finishing of brittle materials can be achieved. The above phenomenon has been substantiated by experimental findings while machining a hard and brittle material, sintered tungsten carbide. The findings suggest that the same concept can be applied for the ductile cutting of other hard and brittle materials.

Theoretical and Experimental Investigation on Inclined Ultrasonic Elliptical Vibration Cutting of Alumina Ceramics

2016 ◽  
Vol 138 (12) ◽  
Author(s):  
Wu-Le Zhu ◽  
Yu He ◽  
Kornel F. Ehmann ◽  
Antonio J. Sánchez Egea ◽  
Xinwei Wang ◽  
...  
Keyword(s):  
Cutting Forces ◽  
Removal Rate ◽  
Polycrystalline Diamond ◽  
Machining Parameters ◽  
Machined Surface ◽  
Pure Alumina ◽  
Elliptical Vibration Cutting ◽  
Vibration Cutting ◽  
Elliptical Vibration ◽  
Ultrasonic Elliptical Vibration

Alumina (Al2O3) is an extremely hard and brittle ceramic that is usually used as an abrasive or a cutting tool insert in manufacturing. However, its growing applications in industrial products make it necessary to conduct a study of the machinability of alumina themselves with a cost-effective and flexible method, rather than conventional diamond grinding or laser-assisted processing methods. In this paper, polycrystalline diamond tools are used to investigate the machining of nonporous pure alumina by applying an inclined ultrasonic elliptical vibration cutting (IUEVC) method. First, a theoretical analysis is presented to study the effects of the machining parameters on cutting performances during raster cutting procedures from the prospective of the material removal rate (MRR), tool-chip contact area, cutting edge angle, etc. Then, experiments are carried out to investigate the cutting forces and the areal surface roughness (Sa) in connection with the theoretically established relationships. The results show that the cutting forces are remarkably reduced, by up to more than 90%, and that the machined surface finish is also improved compared with conventional methods.

Sign in / Sign up

Export Citation Format

Share Document