scholarly journals Numerical Analysis in Ultrasonic Elliptical Vibration Cutting (UEVC) Combined With Electrical Discharge Cutting (EDC) For Ti6Al4V

2021 ◽  
Author(s):  
Rendi Kurniawan ◽  
Moran Xu ◽  
Chang Ping Li ◽  
Gun Chul Park ◽  
Ye In Kwak ◽  
...  
Keyword(s):  
Numerical Analysis ◽  
Cutting Force ◽  
Cutting Forces ◽  
Electrical Discharge ◽  
Von Mises Stress ◽  
Elliptical Vibration Cutting ◽  
Vibration Cutting ◽  
Elliptical Vibration ◽  
Von Mises ◽  
Ultrasonic Elliptical Vibration

Abstract This paper reports the numerical analysis results of ultrasonic elliptical vibration cutting (UEVC) combined with the electrical discharge cutting (EDC), called UEVC+EDC. UEVC delivers decreasing cutting forces, repressing side-burrs, and lowering tool wear. EDC is a cutting technique using a pulsed spark to remove material using thermal energy. Difficult-to-cut materials, such as Ti-6Al-4V, can be cut effectively by combining these two techniques. A numerical study was performed using ABAQUS finite element analysis (FEA) software by investigating the von Mises stress, cutting forces, and temperature. Numerical analysis was carried out by modifying the ultrasonic vibration frequency, distance of the discharge pulse, discharge voltage, and discharge pulse radius. UEVC+EDC was compared numerically and experimentally with regular cutting (NC) and UEVC in terms of cutting force and tool temperature. The results showed that the UEVC+EDC method could improve the cutting condition by reducing the cutting force and von Mises stress and increasing the tool temperature.

A Study on Elliptical Vibration Cutting by Finite Element Analysis

2011 ◽  
Vol 230-232 ◽  
pp. 1029-1033
Author(s):  
Xiao Qin Zhou ◽  
Shao Xin Zhao ◽  
Zhi Wei Zhu ◽  
Jie Qiong Lin ◽  
Dan Luo
Keyword(s):  
Finite Element ◽  
Stress Distribution ◽  
Cutting Forces ◽  
Contact Region ◽  
Equivalent Stress ◽  
Von Mises Stress ◽  
Element Analysis ◽  
Elliptical Vibration Cutting ◽  
Vibration Cutting ◽  
Elliptical Vibration

In order to reveal the mechanistic characteristics during the elliptical vibration cutting (EVC), A simplified 2-D finite element model is developed. The characteristics of the cutting forces during the EVC process are investigated by comparison with the conventional cutting. The results indicate that the lower averaging values of cutting forces can be obtained and an obvious inverse phenomenon of the thrust force is also observed during the EVC process, which may be beneficial to the chip formation. A detailed analysis of the equivalent stress distribution during the EVC process is carried out. A transient stress distribution is observed during the EVC process, the highly localized Von Mises stress in the tool-chip contact region throughout one EVC cycle may help to form a more continuous chip and lead to the ductile regime removal of brittle materials.

Ultrasonic Elliptical Vibration-Assisted Micro-Groove Turning

2014 ◽  
Vol 625 ◽  
pp. 603-606 ◽  
Author(s):  
Chen Zhang ◽  
Kornel Ehmann ◽  
Ying Guang Li ◽  
Ping Guo
Keyword(s):  
Cutting Forces ◽  
Burr Formation ◽  
Ultrasonic Frequency ◽  
Elliptical Vibration Cutting ◽  
Cutting Method ◽  
Vibration Cutting ◽  
Elliptical Vibration ◽  
Comparison Results ◽  
Series Of Experiments ◽  
Ultrasonic Elliptical Vibration

In ultrasonic vibration the cutting edge of a tool is vibrated in the principal or cutting direction, generally at a constant ultrasonic frequency. The main characteristic of this cutting method is its intermittent nature involving repeated cutting and pausing. In this paper, ultrasonic elliptical vibration cutting is used to assist micro-groove turning of cylindrical surfaces. The elliptical locus during the cutting process is generated by a newly designed 2D resonant ultrasonic vibrator. A series of experiments were performed to verify the effects of the ultrasonic elliptical vibrations. The generated cutting forces and burr formation were compared for the ordinary and the elliptical vibration-assisted cases. Comparison results show the effectiveness of the elliptical vibration cutting method in reducing cutting forces and alleviating burr formation.

Micro Hole Elliptical Supersonic Boring Quality Research

2012 ◽  
Vol 217-219 ◽  
pp. 1688-1694
Author(s):  
Ji Liang Wu ◽  
De Yuan Zhang ◽  
Xing Gang Jiang
Keyword(s):  
Cutting Force ◽  
High Quality ◽  
Elliptical Vibration Cutting ◽  
Quality Research ◽  
Vibration Cutting ◽  
Elliptical Vibration ◽  
Longitudinal Excitation ◽  
Micro Hole ◽  
Ultrasonic Elliptical Vibration ◽  
Quality Surface

In this paper a method of ultrasonic elliptical vibration cutting has been applied to precision boring of micro hole due to its superior performances such as low cutting force, high quality surface finish and long tool life. A transducer with the longitudinal excitation is carried out to machining(boring) micro hole of 1Cr18Ni9Ti workpiece. The cutting force and surface quality are studied in detail.The workpiece with surface roughness of Rz 0.4μm is achieved.The results showed that the ultrasonic elliptical vibration transducer can be applied rationally in micro hole precision boring.

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.

Study on the Thrust Cutting Force in Ultrasonic Elliptical Vibration Cutting

2004 ◽  
Vol 471-472 ◽  
pp. 396-400 ◽  
Author(s):  
Chun Xiang Ma ◽  
Eiji Shamoto ◽  
T. Moriwaki
Keyword(s):  
Cutting Force ◽  
Force Model ◽  
Cutting Force Model ◽  
Elliptical Vibration Cutting ◽  
Vibration Cutting ◽  
Elliptical Vibration ◽  
Ultrasonic Elliptical Vibration

In the present paper, the thrust cutting force model in ultrasonic elliptical vibration cutting is proposed based on the principle of ultrasonic elliptical vibration cutting, and the reason of the thrust cutting force reduced by applying ultrasonic elliptical vibration is clarified theoretically. The effect of ultrasonic elliptical vibration on the thrust cutting force is verified experimentally.

scholarly journals Investigation on the Cutting Mechanism of Al/SiCp Composites in Ultrasonic Elliptical Vibration Machining

2021 ◽  
Author(s):  
Wenxiang Chen ◽  
Xu Zhang
Keyword(s):  
Stress Distribution ◽  
Cutting Force ◽  
Surface Integrity ◽  
Machining Process ◽  
Von Mises Stress ◽  
Cutting Mechanism ◽  
Machined Surface ◽  
Elliptical Vibration ◽  
Von Mises ◽  
Ultrasonic Elliptical Vibration

Abstract Aluminum (Al)-based silicon carbide (SiC) material composites are considered as difficult-to-machine materials because of the presence of hard reinforced SiC particles, which results in a greater cutting force and poor surface integrity during the machining process. This paper uses two finite element models to study the difference in the machining mechanism between ultrasonic elliptical vibration cutting (UEVC) and ordinary cutting (OC). Moreover, this paper mainly focuses on the influence of UEVC on cutting force, von Mises stress distribution, surface integrity, and chip formation. The models are validated by comparing chip shapes and machined surface features in OC machining Al/SiCp experience from the literature. Simulation results indicate that the cutting mechanism of Al/SiCp on UEVC is different from that of OC and has several good properties. At the same cutting parameters, high frequency vibration makes the cutting force of UEVC exhibit variable periodicity and reduces average cutting force. The instantaneous impact of tool and fast separation results in a more concentrated von Mises stress distribution, thereby resulting in the particles having a greater break degree than that obtained with OC. A comparison of the surface roughness values from the simulation result shows that UEVC obtains better surface integrity than OC does.

Study on the Cutting Force in Ultrasonic Elliptical Vibration Cutting of Hardened Stainless Steel

2011 ◽  
Vol 55-57 ◽  
pp. 327-331 ◽  
Author(s):  
Cheng Mao Zhang ◽  
Cheng Li ◽  
De Yuan Zhang
Keyword(s):  
Cutting Force ◽  
Stainless Steels ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Elliptical Vibration Cutting ◽  
Vibration Cutting ◽  
Elliptical Vibration ◽  
Feed Force ◽  
Cemented Carbide Tools ◽  
Ultrasonic Elliptical Vibration

Hardened stainless steels are materials widely used in the field of aviation and spaceflight. Machining of this materials with conventional cutting (CC) method is a real challenge compared to other difficult-to-cut materials. Ultrasonic elliptical vibration cutting (UEVC) method is a novel and non-conventional cutting technique which has been successfully applied to machine such intractable materials for the last decade. However, few studies have been conducted on the cutting force in ultrasonic elliptical vibration cutting of hardened materials. This paper presents an experimental study on cutting force in UEVC of hardened stainless steels using cemented carbide tools. Experiments have been carried out to investigate the effect of cutting parameters in the UEVC method in terms of cutting force, while cutting hardened stainless steels. The tests have revealed that the average thrust force,principal force and feed force drop to 3%,10% and 90% of CC value for UEVC of hardened stainless steels. The ratio between the CC force and the UEVC force decrease with the increase of DOC and cutting speed.

Development and optimization of ultrasonic elliptical vibration cutting device based on single excitation

2021 ◽  
pp. 1-29
Author(s):  
Sen Yin ◽  
Zhigang Dong ◽  
Yan Bao ◽  
Renke Kang ◽  
Wenhao Du ◽  
...  
Keyword(s):  
Cutting Speed ◽  
Tungsten Alloy ◽  
Asymmetric Structure ◽  
Diamond Cutting ◽  
Elliptical Vibration Cutting ◽  
Vibration Cutting ◽  
Elliptical Vibration ◽  
Technical Capability ◽  
Diamond Cutting Tool ◽  
Ultrasonic Elliptical Vibration

Abstract Ultrasonic elliptical vibration cutting (UEVC) technique, as an advanced cutting method, has been successfully applied to machine difficult-to-cut materials for the last decade. In this study, the mechanism of the elliptical vibration locus caused by the “asymmetric structure” of the horn was analyzed theoretically firstly, and the corresponding relationship between the degree of asymmetry and the elliptical vibration locus was determined based on finite element method (FEM). Then an efficient single-excitation UEVC device with “asymmetric structure” was developed and optimized. The resonant frequency of the device was 40.8 kHz, and the amplitude reached 12.4 µm, which effectively broke the limitation of cutting speed in UEVC. Finally, the UEVC device's performance was tested, and the advantages in improving the tungsten alloy surface quality and reducing diamond cutting tool wear validated the technical capability and principle of the proposed device.

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