scholarly journals Investigation of tool-workpiece contact rate and milling force in elliptical ultrasonic vibration assisted milling

2021 ◽  
Author(s):  
Zongyuan Li ◽  
Lida Zhu ◽  
Zhichao Yang ◽  
Jian Ma ◽  
Wenbin Cao
Keyword(s):  
Ultrasonic Vibration ◽  
Cutting Speed ◽  
Position Angle ◽  
Force Model ◽  
Contact Rate ◽  
Rate Model ◽  
Milling Force ◽  
Influence Of Process Parameters ◽  
Kinematic Relationship ◽  
Ultrasonic Milling

Abstract Elliptical ultrasonic vibration assisted milling (EUVAM) is widely used as an efficient processing method for hard-to-machining materials such as titanium alloy, superalloy, and hard-brittle materials. To uncover the mechanism of the intermittent cutting characteristics in EUVAM, the tool-workpiece contact rate model is developed by combining with the kinematic relationship between the tool edge and the workpiece in the process. According to the analysis of the contact rate model, the phenomenon that the contact rate increases rapidly with the time-varying tooth position angle in one-dimensional ultrasonic vibration assisted milling can be improved in EUVAM. In addition, considering the variation of window function and undeformed cutting thickness, a force model is established. And the experiment of EUVAM is performed to verify the model of ultrasonic milling force, and the influence of process parameters (amplitude, cutting speed, feed rate and cutting depth) on ultrasonic milling force is also analyzed.

scholarly journals Research on Stability of Robotic Longitudinal-Torsional Ultrasonic Milling With Variable Cutting Force Coefficient

2021 ◽  
Author(s):  
Jianlong Zhang ◽  
Wei Zhao ◽  
Bo Li ◽  
Wei Tian ◽  
Kan Zheng ◽  
...  
Keyword(s):  
Industrial Robots ◽  
Cnc Machine Tools ◽  
Force Model ◽  
Cnc Machine ◽  
Force Coefficient ◽  
Milling Force ◽  
Reinforced Plastics ◽  
Ultrasonic Milling ◽  
Cutting Force Coefficient ◽  
Milling Force Model

Abstract With their successful applications in handling, spraying, arc welding and other processing fields, industrial robots are gradually replacing traditional CNC machine tools to complete machining tasks due to the wider working envelope and the higher flexibility. Aiming at the chatter problem, a robotic longitudinal-torsional ultrasonic milling method with variable force coefficient is proposed in this paper. Taking Carbon Fiber Reinforced Plastics (CFRP) as the processing object, the influence of the fiber layup angle on the milling force are analyzed first; then the robot milling force parameters are determined and the robot milling kinematics model is established. Furthermore, the ultrasonic function angle is defined, and the cutting layer thickness model, the dynamic milling force model and the dynamic differential equation under ultrasonic vibration are established to analyze the stability of robotic longitudinal-torsional ultrasonic milling of CFRP. Finally, the full discrete method is used to obtain stability lobe diagrams.

scholarly journals Z-Map Based Cutting Force Prediction for Elliptical Ultrasonic Vibration-Assisted Milling Process

2021 ◽  
Author(s):  
Zhongqun Li ◽  
Jiandong Xiao Xiao ◽  
Xiong HAN ◽  
Weifeng ZHANG
Keyword(s):  
Cutting Force ◽  
Ultrasonic Vibration ◽  
High Frequency ◽  
Cutting Speed ◽  
Milling Process ◽  
Force Model ◽  
Cutting Force Prediction ◽  
Hard And Brittle Materials ◽  
The Impact ◽  
Intermittent Cutting

Abstract Elliptical ultrasonic vibration-assisted milling (EUVAM) adds high-frequency vibration to conventional milling (CM) to realize high-frequency intermittent milling. It has broad application prospects in the processing of difficult-to-cut materials such as titanium alloys, superalloys and hard and brittle materials. To reveal the mechanism of the highly intermittent cutting nature in EUVAM, according to the motion relationship between cutting edge and workpiece and the Z-map model of the workpiece, a method and its algorithm for calculating undeformed cutting thickness and thus the cutting force in EUVAM are proposed. The simulation results show that EUVAM can improve the actual cutting speed when compared with CM, and the proportion of idle cutting time will directly determine the intermittent degree of the milling process. The experiment of EUVAM is performed to verify the correctness of the proposed cutting force model, and the impact of spindle speed on the cutting force in EUVAM is also analyzed.

Milling force model for asymmetric end-mills during high-feed milling on AISI-P20

2021 ◽  
pp. 1-8
Author(s):  
Diego Russo ◽  
Gorka Urbicain ◽  
Antonio J. Sánchez Egea ◽  
Alejandro Simoncelli ◽  
Daniel Martinez Krahmer
Keyword(s):  
Force Model ◽  
Milling Force ◽  
Aisi P20 ◽  
High Feed ◽  
End Mills ◽  
Milling Force Model

scholarly journals An Investigation of the High-Frequency Ultrasonic Vibration-Assisted Cutting of Steel Optical Moulds

Micromachines ◽  
2021 ◽  
Vol 12 (4) ◽  
pp. 460
Author(s):  
Canbin Zhang ◽  
Chifai Cheung ◽  
Benjamin Bulla ◽  
Chenyang Zhao
Keyword(s):  
Surface Roughness ◽  
Ultrasonic Vibration ◽  
High Frequency ◽  
Optical Glass ◽  
Contact Point ◽  
Cutting Speed ◽  
Optical Quality ◽  
Machining Parameters ◽  
Nose Radius ◽  
Cutting Geometry

Ultrasonic vibration-assisted cutting (UVAC) has been regarded as a promising technology to machine difficult-to-machine materials such as tungsten carbide, optical glass, and hardened steel in order to achieve superfinished surfaces. To increase vibration stability to achieve optical surface quality of a workpiece, a high-frequency ultrasonic vibration-assisted cutting system with a vibration frequency of about 104 kHz is used to machine spherical optical steel moulds. A series of experiments are conducted to investigate the effect of machining parameters on the surface roughness of the workpiece including nominal cutting speed, feed rate, tool nose radius, vibration amplitude, and cutting geometry. This research takes into account the effects of the constantly changing contact point on the tool edge with the workpiece induced by the cutting geometry when machining a spherical steel mould. The surface morphology and surface roughness at different regions on the machined mould, with slope degrees (SDs) of 0°, 5°, 10°, and 15°, were measured and analysed. The experimental results show that the arithmetic roughness Sa of the workpiece increases gradually with increasing slope degree. By using optimised cutting parameters, a constant surface roughness Sa of 3 nm to 4 nm at different slope degrees was achieved by the applied high-frequency UVAC technique. This study provides guidance for ultra-precision machining of steel moulds with great variation in slope degree in the pursuit of optical quality on the whole surface.

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.

Milling Force Prediction for Circular Contour Machining

2014 ◽  
Vol 800-801 ◽  
pp. 243-248
Author(s):  
Kai Zhao ◽  
Zhan Qiang Liu
Keyword(s):  
Prediction Model ◽  
Milling Process ◽  
Machining Process ◽  
Curvature Radius ◽  
Force Model ◽  
Milling Force ◽  
Circular Contour ◽  
The Mean ◽  
Contour Machining ◽  
Matlab Programming

When machining the complex parts of aircraft engines, the milling force for the circular contour must be accurately predicted to reduce machining vibration. In this paper, the prediction model of the mean milling force per tooth during machining circular contour is developed. Firstly, the formulas of the entry angle, the exit angle and the equivalent feed per tooth are established through the analysis of circular contour milling process. Then, the equation of the mean milling force per tooth is deduced based on mechanistic force model during the circular contour machining process. Finally, the prediction model of mean milling force per tooth during machining circular contour is developed using MATLAB programming. The relationship between the milling force per tooth and surface curvature radius of the machined workpiece is also analyzed in this paper.

scholarly journals Optimization of Drilling Process Parameters Via Taguchi, TOPSIS and RSA Techniques

2017 ◽  
Vol 62 (3) ◽  
pp. 1803-1812 ◽  
Author(s):  
K. Shunmugesh ◽  
K. Panneerselvam
Keyword(s):  
Process Parameters ◽  
Feed Rate ◽  
Research Work ◽  
Cutting Speed ◽  
High Strength ◽  
Drilling Process ◽  
Drill Bit ◽  
Influence Of Process Parameters ◽  
Light Trucks ◽  
Cfrp Composite

AbstractCarbon Fiber Reinforced Polymer (CFRP) is the most preferred composite material due to its high strength, high modulus, corrosion resistance and rigidity and which has wide applications in aerospace engineering, automobile sector, sports instrumentation, light trucks, airframes. This paper is an attempt to carry out drilling experiments as per Taguchi’s L27(313) orthogonal array on CFRP under dry condition with three different drill bit type (HSS, TiAlN and TiN). In this research work Response Surface Analysis (RSA) is used to correlate the effect of process parameters (cutting speed and feed rate) on thrust force, torque, vibration and surface roughness. This paper also focuses on determining the optimum combination of input process parameter and the drill bit type that produces quality holes in CFRP composite laminate using Multi-objective Taguchi technique and TOPSIS. The percentage of contribution, influence of process parameters and adequacy of the second order regression model is carried out by analysis of variance (ANOVA). The results of experimental investigation demonstrates that feed rate is the pre-dominate factor which affects the response variables.

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