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.

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.

Edge Trimming of CFRP Composites Using Rotary Ultrasonic Machining: Effects of Ultrasonic Vibration

2018 ◽  
Author(s):  
Hui Wang ◽  
Fuda Ning ◽  
Yingbin Hu ◽  
Yuanchen Li ◽  
Xinlin Wang ◽  
...  
Keyword(s):  
Ultrasonic Vibration ◽  
Machining Process ◽  
Ultrasonic Machining ◽  
Rotary Ultrasonic Machining ◽  
Machining Performance ◽  
Machining Processes ◽  
Cfrp Composites ◽  
Abrasive Properties ◽  
Vibration Assistance ◽  
Edge Trimming

Carbon fiber reinforced plastic (CFRP) composites have many excellent properties, which make them be widely used in many applications. After demolding processes, CFRP composites still need additional machining processes to achieve final shape with desired tolerances. Edge trimming is the first machining process performed on composites after their molding processes. Because of carbon fibers’ abrasive properties as well as CFRPs’ properties of inhomogeneity and anisotropy, CFRPs are regarded as the difficult-to-cut materials. Many problems are generated in traditional machining processes. To reduce and solve the problems, edge trimming using rotary ultrasonic machining (RUM) is reported in this manuscript. This paper, for the first time, makes the comparisons on machining performance (cutting forces, torque, and surface roughness) between edge trimming processes with and without ultrasonic vibration assistance. To better understand effects of ultrasonic vibration on such a process, machining mechanisms are also obtained and analyzed. This paper will provide guides for RUM edge trimming of CFRP composites.

Rotary Ultrasonic Machining: Effects of Tool End Angle on Delamination of CFRP Drilling

2017 ◽  
Author(s):  
Palamandadige K. S. C. Fernando ◽  
Meng (Peter) Zhang ◽  
Zhijian Pei ◽  
Weilong Cong
Keyword(s):  
Carbon Fiber ◽  
Material Removal ◽  
Ultrasonic Machining ◽  
Fiber Reinforced ◽  
Rotary Ultrasonic Machining ◽  
Carbon Fiber Reinforced Plastics ◽  
Reinforced Plastics ◽  
Hole Making ◽  
Fiber Reinforced Plastics ◽  
Carbon Fiber Reinforced

Aerospace, automotive and sporting goods manufacturing industries have more interest on carbon fiber reinforced plastics due to its superior properties, such as lower density than aluminum; higher strength than high-strength metals; higher stiffness than titanium etc. Rotary ultrasonic machining is a hybrid machining process that combines the material removal mechanisms of diamond abrasive grinding and ultrasonic machining. Hole-making is the most common machining operation done on carbon fiber reinforced plastics, where delamination is a major issue. Delamination reduces structural integrity and increases assembly tolerance, which leads to rejection of a part or a component. Comparatively, rotary ultrasonic machining has been successfully applied to hole-making in carbon fiber reinforced plastics. As reported in the literature, rotary ultrasonic machining is superior to twist drilling of carbon fiber reinforced plastics in six aspects: cutting force, torque, surface roughness, delamination, tool life, and material removal rate. This paper investigates the effects of tool end angle on delamination in rotary ultrasonic machining of carbon fiber reinforced plastics. Several investigators have cited thrust force as a major cause for delamination. Eventhogh, it is found on this investigation, tool end angle has more significant influence on the delamination in rotary ultrasonic machining of carbon fiber reinforced plastics comparing to cutting force and torque.

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.

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.

Surface Grinding of ZTA Parts Fabricated by Laser Engineered Net Shaping Process: Effects of ZrO2 Content and Ultrasonic Vibration

2018 ◽  
Author(s):  
Yingbin Hu ◽  
Hui Wang ◽  
Yuanchen Li ◽  
Fuda Ning ◽  
Weilong Cong
Keyword(s):  
Surface Roughness ◽  
Cutting Force ◽  
Surface Quality ◽  
Ultrasonic Vibration ◽  
Machining Process ◽  
Ultrasonic Machining ◽  
Zro2 Content ◽  
Laser Engineered Net Shaping ◽  
Process Effects ◽  
Net Shaping

The zirconia toughened alumina (ZTA) parts fabricated by laser engineered net shaping (LENS) process demonstrate problems resulted from poor surface quality. To improve surface quality and to reduce related problems, rotary ultrasonic machining (RUM) process, which combines both grinding process and ultrasonic machining process, has been introduced. In this investigation, the effects of ZrO2 content and ultrasonic vibration on flatness, surface roughness, microhardness, and cutting force in feeding direction of LENS-fabricated ZTA parts have been studied. Results showed that with the ZrO2 content increasing, the flatness value increased, the surface roughness value decreased, and the microhardness value firstly increased then decreased. Compared with LENS-fabricated parts, the parts processed by RUM machine exhibited better surface quality with significantly reduced flatness value and surface roughness value. In RUM process, the introduction of ultrasonic vibration was beneficial for reducing 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.

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.

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