Generation mechanism modeling of surface topography in tangential ultrasonic vibration-assisted grinding with green silicon carbide abrasive wheel

2021 ◽  
pp. 095440542110406
Author(s):  
Yutong Qiu ◽  
Jingfei Yin ◽  
Yang Cao ◽  
Wenfeng Ding
Keyword(s):  
Surface Roughness ◽  
Surface Topography ◽  
Ultrasonic Vibration ◽  
Generation Mechanism ◽  
Surface Generation ◽  
Depth Of Cut ◽  
Abrasive Wheel ◽  
Grinding Parameters ◽  
Conventional Grinding ◽  
Ultrasonic Vibration Assisted Grinding

Tangential ultrasonic vibration-assisted grinding (TUAG) has a wide prospect in machining difficult-to-machine materials. However, the surface generation mechanism in TUAG is not fully recovered. This study proposes an analytical model of the surface topography produced by TUAG. Based on the model, the surface topography and roughness are predicted and experimentally verified. In addition, the influence of the grinding parameters on the surface topography is analyzed. The predicted surface topography well coincides with experimental measurements, and the prediction error in surface roughness Ra by the proposed model is less than 5%. Compared with conventional grinding, TUAG produces a surface with more uniform scratches and surface roughness Ra was reduced by up to 27% with the proper parameters. However, the improvement of surface roughness in TUAG is weakened when grinding speed or depth of cut increases. Moreover, the influence of the ultrasonic vibration amplitude on the surface roughness is not monotonous. With the grinding parameters selected in this study, TUAG with an ultrasonic amplitude of 7.5 μm produces the minimum surface roughness.

Investigation on Machined Surface Roughness in Ultrasonic Vibration Assisted Grinding (I)

2011 ◽  
Vol 230-232 ◽  
pp. 829-833
Author(s):  
Hong Li Zhang ◽  
Shao Fu Shan ◽  
Jian Hua Zhang
Keyword(s):  
Surface Roughness ◽  
Surface Morphology ◽  
Ultrasonic Vibration ◽  
Machined Surface ◽  
Conventional Grinding ◽  
Machined Surface Roughness ◽  
Ultrasonic Vibration Assisted Grinding ◽  
Abrasive Size ◽  
Calculating Model

Based on the generating mechanism of surface morphology by tangential ultrasonic vibration assisted grinding (TUAG), the calculating model for surface roughness is established and the surface roughness experiments are conducted both in TUAG and conventional grinding (CG). The results indicate that the effect of the grinding abrasive size on the surface roughness is the most obvious, and the surface roughness is decreased due to the tangential ultrasonic vibration.

Deep Hole Machining with a Small Diameter Drill and Ultrasonic Vibration

2017 ◽  
Vol 749 ◽  
pp. 107-110
Author(s):  
Yuta Masu ◽  
Tomohito Fukao ◽  
Taiga Yasuki ◽  
Masahiro Hagino ◽  
Takashi Inoue
Keyword(s):  
Surface Roughness ◽  
Ultrasonic Vibration ◽  
Cutting Tool ◽  
Cutting Speed ◽  
Small Diameter ◽  
Maximum Amplitude ◽  
Depth Of Cut ◽  
Deep Hole ◽  
Work Material ◽  
Finished Surface

The method of imparting ultrasonic vibration to the cutting tool is known to improve the shape accuracy and finished surface roughness. However, a uniform evaluation of this function in drilling has not been achieved, and the cutting process cannot be checked from the outside. The aim of this study is to investigate the cutting characteristics in deep hole drilling when an ultrasonic vibrator on the table of a machining center provides vibration with a frequency of 20 kHz to the work piece. The ultrasonic vibrations in this system reach the maximum amplitude in the center of the work material. We evaluated the change in finished surface roughness between the section where drilling starts to the point of maximum amplitude with ultrasonic vibration. The main cutting conditions are as follows: cutting speed (V) 12.6 (mm/min); feed rate (s) 30, 60 (mm/rev); depth of cut (t) = 32 (mm); work material, tool steel; cutting tool material, HSS; point angle (σ) 118 (°); and drill diameter (φ) 4 (mm). Lubricant powder was also added to clarify the cutting effect, and compared the condition in which there was no ultrasonic vibration. The results showed that surface roughness at the point of maximum amplitude was better than that with no vibration.

Optimization of Surface Roughness in Centreless Grinding Process Based on Taguchi Method

2021 ◽  
pp. 37-47
Author(s):  
Prosun Mandal
Keyword(s):  
Surface Roughness ◽  
Taguchi Method ◽  
Wheel Speed ◽  
Depth Of Cut ◽  
Grinding Process ◽  
Signal To Noise ◽  
Grinding Parameters ◽  
Medium Level ◽  
Grinding Conditions ◽  
Valve Opening

This chapter aims to optimize centreless grinding conditions using the Taguchi method for minimizing surface roughness. The grinding operation has been performed according to the L9 orthogonal array in a centreless grinding process. The centreless grinding experiments are carried out on the crane-hook pin of C40 steel. The analysis of variance (ANOVA) and computation of signal to noise (S/N) ratio are adopted to determine the influence of grinding parameters (depth of cut [µm], regulating wheel speed [rpm], and coolant valve opening) on surface roughness. The depth of cut (µm) is found to be the most significant among the grinding parameters on the surface roughness. The signal to noise (S/N) ratio was calculated based on smaller the best criteria. The lower level of depth of cut, medium level of regulating wheel speed, and higher-level coolant valve opening is found to be optimal grinding condition according to the mean response and signal to noise (S/N) ratio.

scholarly journals Effect to the Surface Composition in Ultrasonic Vibration-Assisted Grinding of BK7 Optical Glass

2020 ◽  
Vol 10 (2) ◽  
pp. 516 ◽  
Author(s):  
Pei Yi Zhao ◽  
Ming Zhou ◽  
Xian Li Liu ◽  
Bin Jiang
Keyword(s):  
Surface Roughness ◽  
Ultrasonic Vibration ◽  
Material Removal ◽  
Surface Composition ◽  
Rotation Speed ◽  
Optical Glass ◽  
Machined Surface ◽  
Spindle Rotation ◽  
Ultrasonic Vibration Assisted Grinding ◽  
Ductile Removal

Because of the changes in cutting conditions and ultrasonic vibration status, the proportion of multiple material removal modes are of uncertainty and complexity in ultrasonic vibration-assisted grinding of optical glass. Knowledge of the effect of machined surface composition is the basis for better understanding the influence mechanisms of surface roughness, and also is the key to control the surface composition and surface quality. In the present work, 32 sets of experiments of ultrasonic vibration-assisted grinding of BK7 optical glass were carried out, the machined surface morphologies were observed, and the influence law of machining parameters on the proportion of different material removal was investigated. Based on the above research, the effect of surface composition was briefly summarized. The results indicated that the increasing of spindle rotation speed, the decreasing of feed rate and grinding depth can improve the proportion of ductile removal. The introduction of ultrasonic vibration can highly restrain the powdering removal, and increase the proportion of ductile removal. Grinding depth has a dominant positive effect on the surface roughness, whereas the spindle rotation speed and ultrasonic amplitude both have negative effect, which was caused by the reduction of brittle fracture removal.

scholarly journals Laser-assisted grinding of reaction-bonded SiC

2020 ◽  
Vol 3 (2) ◽  
pp. 93-98
Author(s):  
Xichun Luo ◽  
Zhipeng Li ◽  
Wenlong Chang ◽  
Yukui Cai ◽  
Jining Sun ◽  
...  
Keyword(s):  
Surface Roughness ◽  
Process Development ◽  
Thermal Control ◽  
Subsurface Damage ◽  
Experimental Comparison ◽  
Depth Of Cut ◽  
Machined Surface ◽  
Control Approach ◽  
Damage Layer ◽  
Conventional Grinding

The article presents the development of a novel laser-assisted grinding (LAG) process to reduce surface roughness and subsurface damage in grinding reaction-bonded silicon carbide (RB-SiC). A thermal control approach is proposed to facilitate the process development, in which a two-temperature model (TTM) is applied to control the required laser power to thermal softening of RB-SiC prior to the grinding operation without melting the workpiece or leaving undesirable microstructural alteration. Fourier’s law is adopted to obtain the thermal gradient for verification. An experimental comparison of conventional grinding and LAG shows significant reduction of machined surface roughness (37%–40%) and depth of subsurface damage layer (22%–50.6%) using the thermal control approach under the same grinding conditions. It also shows high specific grinding energy 1.5 times that in conventional grinding at the same depth of cut, which accounts for the reduction of subsurface damage as it provides enough energy to promote ductile-regime material removal.

Investigation on surface quality of high-speed cutting titanium alloy Ti6Al4V based on Split-Hopkinson pressure bar

2020 ◽  
Vol 234 (10) ◽  
pp. 1293-1301 ◽  
Author(s):  
Zhanfei Zhang ◽  
Zengqiang Wang ◽  
Wenhu Wang ◽  
Ruisong Jiang ◽  
Yifeng Xiong
Keyword(s):  
Surface Roughness ◽  
Surface Topography ◽  
Surface Quality ◽  
High Speed ◽  
Split Hopkinson Pressure Bar ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
Hopkinson Pressure Bar ◽  
High Speed Cutting ◽  
Pressure Bar

High-speed cutting technology has the characteristics of high material removal rate and excellent processing quality. To investigate the surface quality of high-speed cutting Ti6Al4V alloy, the orthogonal cutting experiment is the cutting device based on improved Split-Hopkinson pressure bar carried out with a cutting speed of about 7–16 m/s. Surface roughness, residual stress and three-dimensional surface topography are examined to characterize the surface quality. And the chip geometry parameters are measured to analyze the formation mechanism of surface topography. The result shows that cutting force and surface roughness increase rapidly with the increase in depth of cut. In the meantime, the periodic microwaves appeared on the machined surface, and their amplitudes increase with the increase in depth of cut. However, surface roughness, residual stress and microwave amplitude all decrease with the increase in cutting speed. Moreover, it is found that the evolution trend of chip thickness and surface roughness with cutting parameters is very similar. Therefore, it can be inferred that there is a strong relationship between surface topography and chip morphology.

Experimental study on the surface roughness of micromilled Elgiloy™

2011 ◽  
Vol 225 (11) ◽  
pp. 2138-2143 ◽  
Author(s):  
P Zhang ◽  
B Wang ◽  
Y Liang ◽  
M J Jackson
Keyword(s):  
Experimental Study ◽  
Surface Roughness ◽  
Surface Topography ◽  
Industrial Applications ◽  
Depth Of Cut ◽  
Mean Deviation ◽  
Machining Accuracy ◽  
Feed Speed ◽  
3D Surface ◽  
Axial Depth

Elgiloy™ is a cobalt-based alloy with excellent physical and chemical performance, and is used widely in medical and industrial applications. The machining accuracy, surface topography, and surface damaged layer play an important role in the use of the alloy for specific applications. In this paper, an experimental study on the surface roughness of precision micromilling of Elgiloy is accomplished by using a super-fine-grained tungsten carbide milling cutter. The surface topography of the surface of the slots milled is achieved with different values of feed speed and axial depth of cut. Three-dimensional (3D) measurement results are considered to reflect the surface topography based on a comparison of the difference between two-dimensional (2D) and 3D surface roughness measurements. The arithmetic mean deviation of the slots’ 3D surface is achieved by using a white light interferometric profilometer. By using analysis of variance (ANOVA), the factors of feed speed, axial depth of cut, and their interaction are proven to be the most important factors relating to the magnitude of surface roughness.

A Two-Dimensional Ultrasonically Assisted Grinding Technique for High Efficiency Machining of Sapphire Substrate

2009 ◽  
Vol 626-627 ◽  
pp. 35-40 ◽  
Author(s):  
Z. Liang ◽  
Yong Bo Wu ◽  
Xin Bing Wang ◽  
Y. Peng ◽  
Wei Xing Xu ◽  
...  
Keyword(s):  
Ultrasonic Vibration ◽  
Sapphire Substrate ◽  
High Efficiency ◽  
Vibration Mode ◽  
Two Dimensional ◽  
Grinding Forces ◽  
Work Surface ◽  
Conventional Grinding ◽  
Grinding Technique ◽  
Ultrasonic Vibration Assisted Grinding

This paper discusses the feasibility of improving machining efficiency of sapphire substrate by using two-dimensional (2D) ultrasonic vibration assisted grinding. An elliptic ultrasonic vibrator is designed and produced by bonding a piezoelectric ceramic device (PZT) on a metal elastic body (stainless steel, SUS304). The sapphire substrate is fixed onto the top face of the vibrator and ultrasonically vibrates in 2D vibration mode when the PZT is excited by two alternating current voltages with a phase difference. A grinding apparatus mainly composed of the ultrasonic vibrator is constructed, and experiments are performed with lateral modulation of elliptic ultrasonic vibration vertical to the grinding direction. Both the grinding forces and the ground work surface are measured and examined. Experimental results show that the grinding force decreases significantly and the resulted surface is improved in certain degree with the ultrasonic vibration compared to those of conventional grinding without ultrasonication. This indicates that the high efficiency grinding for sapphire substrate can be performed with the two-dimensional vibration grinding technique presented in this paper.

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