scholarly journals Analytical and Experimental Investigation on Cutting Force in Longitudinal-Torsional Coupled Rotary Ultrasonic Machining Zirconia Ceramics

2021 ◽  
Author(s):  
Fan Chen ◽  
Wenbo Bie ◽  
Yingli Chang ◽  
Bo Zhao ◽  
Xiaobo Wang ◽  
...  
Keyword(s):  
Cutting Force ◽  
Material Removal ◽  
Processing Parameters ◽  
Force Model ◽  
Ultrasonic Machining ◽  
Removal Mechanism ◽  
Rotary Ultrasonic Machining ◽  
Material Removal Mechanism ◽  
Zirconia Ceramics ◽  
The Impact

Abstract Ceramics and other hard-and-brittle materials are very effectively processed by longitudinal-torsional coupled rotary ultrasonic machining (LTC-RUM). However, the cutting force evolution and the effects of processing parameters on the material removal mechanism in LTC-RUM need to be clarified for machining optimization. This paper proposes a cutting force model of the LTC-RUM of zirconia ceramics via the brittle material removal mechanism. Firstly, the kinematic analysis of a single abrasive grain was performed, with further consideration of the material removal volume, the effective contact time, and the impact force per one ultrasonic vibration cycle. Then, the longitudinal-torsional coupled vibration of the core tool was analyzed from the standpoint of wave energy conversion. The analytical model was finalized and experimentally verified by LTC-RUM tests. The cutting force curves predicted via the proposed model were in good agreement with the experimental results. The results obtained are considered instrumental in predicting the effects of processing parameters on cutting force during LTC-RUM of ceramics and their further optimization.

The Research and Development on the Material Removal Mechanism of the Ultrasonic Cutting

2014 ◽  
Vol 1027 ◽  
pp. 40-43
Author(s):  
Yan Yan Lou ◽  
Yan Zhang ◽  
Ying Gao ◽  
Jia Chen Zhang ◽  
Yan Zhou Sun
Keyword(s):  
Material Removal ◽  
Development Trend ◽  
Ultrasonic Machining ◽  
Removal Mechanism ◽  
Rotary Ultrasonic Machining ◽  
Material Removal Mechanism ◽  
Material Removal Model ◽  
The Development Trend ◽  
Removal Model ◽  
Ultrasonic Cutting

Ultrasonic machining is an important part of modern processing technology which is adapt to all kinds of hard brittle materials processing. This paper reviews the latest progress of the material removal mechanism on one-dimensional ultrasonic machining, two-dimensional ultrasonic machining and rotary ultrasonic machining, and expounds the development trend of establishing the material removal model of the ultrasonic machining.

FEM Investigation of Damage Evolution at Elevated Temperatures With Multiple Impact Hits in Vibration Assisted Nano Impact Machining by Loose Abrasives

2019 ◽  
Author(s):  
Nick H. Duong ◽  
Jianfeng Ma ◽  
Shuting Lei ◽  
Murali Sundaram ◽  
Muhammad P. Jahan
Keyword(s):  
Material Removal ◽  
Elevated Temperatures ◽  
Operating Temperature ◽  
Computational Study ◽  
Frictional Coefficient ◽  
Impact Angle ◽  
Removal Mechanism ◽  
Material Removal Mechanism ◽  
Multiple Impact ◽  
The Impact

Abstract In this paper, a computational study of a novel nanomachining process, Vibration Assisted Nano Impact machining by Loose Abrasives (VANILA), is conducted using the commercial FEM software package ABAQUS. In this novel nanomachining process, an atomic force microscope (AFM) is utilized as a platform and the nano abrasives are injected in the slurry which is located between the workpiece and the vibrating AFM probe. These nano abrasives impact the workpiece and result in nanoscale material removal. In this research, diamond particles are used as loose abrasives and the ductile mode machining is used to describe the behavior of the brittle silicon workpiece. This study aims to investigate the effects of operating temperature and number of multiple impact hits on material removal mechanism of VANILA process. The impact speed of the loose abrasives is kept constant at 200 m/s and the impact angle is fixed at 90°. The frictional coefficient during the machining is considered to be 0.05. The material removal mechanism at various operating temperatures (20°C, 100°C, 200°C, 400°C, 600°C, and 800°C) and multiple impacts are tested. It is found that the operating temperature and number of impact hits have substantial influence on material removal volume in the VANILA process.

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.

Comparison of Material Removal Characteristics in Single and Multiple Cutting Edge Scratches

2013 ◽  
Vol 797 ◽  
pp. 189-195 ◽  
Author(s):  
Xun Chen ◽  
Tahsin Tecelli Öpöz
Keyword(s):  
Cutting Force ◽  
Specific Energy ◽  
Material Removal ◽  
Experimental Results ◽  
Multiple Edge ◽  
Test Material ◽  
Grinding Process ◽  
Removal Mechanism ◽  
Material Removal Mechanism ◽  
Single Edge

This paper presents the important characteristics of material removal mechanism during single grit scratching test. Material removal mechanism in these scratches shows cutting and ploughing action varies with the number of cutting edges leading to different cutting force and specific energy. According to experimental results, single edge scratches are more efficient cutting while multiple edge scratches give more ploughing actions, which consume energy with little contribution to materials removal. The results provided an important insight of material removal during grinding process.

An experimental study on rotary ultrasonic machining of Macor ceramic

2016 ◽  
Vol 232 (7) ◽  
pp. 1221-1234 ◽  
Author(s):  
Ravi Pratap Singh ◽  
Sandeep Singhal
Keyword(s):  
Material Removal Rate ◽  
Material Removal ◽  
Removal Rate ◽  
Ultrasonic Power ◽  
Ultrasonic Machining ◽  
Rotary Ultrasonic Machining ◽  
Desirability Approach ◽  
Index Value ◽  
The Impact ◽  
Desirability Index

Macor ceramic has been well recognized as an eminent engineering material which possesses enlarged industrial usage owing to its excellent and versatile properties. However, its fruitful and economic processing is still unanswered. This article has targeted to experimentally investigate the influence of numerous process variables on machining characteristics in rotary ultrasonic machining of Macor ceramic. The impact of different input factors, namely, spindle speed, feed rate, coolant pressure, and ultrasonic power has been appraised on process responses of interest, that is, material removal rate and chipping size. The experimental plan was designed by employing response surface methodology through central composite rotatable design. The variance analysis test has also been performed with a view to observe the significance of considered parameters. Microstructure of machined samples has also been evaluated and analyzed using scanning electron microscope. This analysis has revealed and confirmed the presence of dominated brittle fracture that caused removal of material along with the thin plastic deformation in rotary ultrasonic machining of Macor ceramic. The reliability and competence of the developed mathematical model have been established with test results. The multi-response optimization of machining responses has also been done by utilizing desirability approach, and at optimized parametric setting, the obtained experimental values for material removal rate and chipping size are 0.4762 mm3/s and 0.3718 mm, respectively, with the combined desirability index value of 0.937.

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