scholarly journals Rotary Ultrasonic Machining of Alumina Ceramic: An Experimental Investigation of Tool Path and Tool Overlapping

2020 ◽  
Vol 10 (5) ◽  
pp. 1667 ◽  
Author(s):  
Basem M. A. Abdo ◽  
Abdualziz El-Tamimi ◽  
Emad Abouel Nasr
Keyword(s):  
Surface Roughness ◽  
Surface Morphology ◽  
Surface Quality ◽  
Tool Path ◽  
Removal Rate ◽  
Ultrasonic Machining ◽  
Rotary Ultrasonic Machining ◽  
Roughness Surface ◽  
Tool Wear Mechanisms

Pocket milling has been regarded as one of the most widely used operations in machining. The surface quality of the machined pockets is an essential aspect of any engineering and medical applications. In the current study, rotary ultrasonic machining (RUM) was applied for milling micro-pockets on alumina (Al2O3) ceramic. The objective of this research was to analyze the effect of the tool overlapping parameters on the surface roughness, surface morphology and the profiles of the machined pockets. Subsequently, the effect of different tool path strategies was analyzed on the surface quality and the material removal rate (MRR) of the machined pockets. A scanning electron microscope is used for analyzing the tool wear mechanisms. The experimental results provide evidence that the surface roughness, surface morphology and the MRR have been significantly affected by the considered tool overlapping and the tool path strategies. Furthermore, among the selected tool overlapping parameters (5–25%) and the tool path strategies, the best surface roughness (Ra = 0.155 μm and Rt = 1.432 µm) of the machined pockets can be found at 20% of the tool overlapping with a mix of uni-directional and zigzag tool path strategy.

The Surface Quality Experimental Analysis of Rotary Ultrasonic Machining

2013 ◽  
Vol 419 ◽  
pp. 348-354 ◽  
Author(s):  
Chao Liang Xu ◽  
Xiao Hua Tang ◽  
Tian Yu Xia
Keyword(s):  
Surface Roughness ◽  
Surface Quality ◽  
Brittle Materials ◽  
Zirconia Ceramic ◽  
Ultrasonic Machining ◽  
Rotary Ultrasonic Machining ◽  
Ultrasonic Machine ◽  
Mechanical Machining ◽  
Better Than

Rotary ultrasonic machining (RUM) is widely used for machining virous kinds of hard-brittle materials. This article aims to study ultrasonic machining surface quality of zirconia ceramic, low-carbonsteel boltwith self-developed rotary ultrasonic machine. The surface roughness could be detected and observed by Taylor Hobson surface roughness instrument and Keyence microscope.The experimental resultsshow that the surface quality achieved by rotary ultrasonic machining is better than bytraditional mechanical machining. Rotary ultrasonic machininghas advantages for machining hard-brittle materials.

EVALUATION OF A REGRESSION PREDICTION MODEL FOR SURFACE ROUGHNESS OF WOOD–POLYETHYLENE COMPOSITE (WPC)

2017 ◽  
Vol 24 (Supp02) ◽  
pp. 1850033
Author(s):  
WENYONG SHI ◽  
YAN MA ◽  
CHUNMEI YANG ◽  
BIN JIANG ◽  
ZHE LI
Keyword(s):  
Surface Roughness ◽  
Surface Morphology ◽  
Prediction Model ◽  
Surface Quality ◽  
Cutting Parameters ◽  
Wood Powder ◽  
Polyethylene Composite ◽  
Milled Surface ◽  
Powder Content

Milling processing is an important way to obtain wood–polyethylene composite (WPC) end products. In order to improve the processing efficiency and surface quality of WPC and meet the practical application requirements, this paper focussed on morphology and roughness of the WPC-milled surface and studied surface quality changes under different cutting parameters and milling methods through multi-parameters milling experiments. The milling surface morphology and roughness of WPC were analyzed and measured during cut-in, cutting and cut-out sections. It also revealed the affect rule of different cutting parameters and milling methods on milled surface morphology and roughness. The results show that the milling surface roughness of WPC products with wood powder content of 70% is significantly larger than the one whose wood powder content is 60%, and defects such as holes are also relatively more. Finally, a surface roughness prediction model was established based on the mathematical regression method and its multi-factor simulation was carried out. A comparative analysis of predictive and experimental values was performed to verify the reliability of the model. It could also provide theoretical guidance and technical guarantee for high processing quality of WPC milling and cutting.

Fixed Abrasive Lapping and Polishing of Hard Brittle Materials

2010 ◽  
Vol 426-427 ◽  
pp. 589-592 ◽  
Author(s):  
Jun Li ◽  
Yong Wei Zhu ◽  
Dun Wen Zuo ◽  
Kui Lin ◽  
M. Li
Keyword(s):  
Surface Roughness ◽  
Surface Quality ◽  
Removal Rate ◽  
Brittle Materials ◽  
Process Conditions ◽  
High Productivity ◽  
Fixed Abrasive ◽  
K9 Glass ◽  
Panel Glass

Fixed abrasive lapping and polishing (FALP) is a new machining technology and was adopted to manufacture hard brittle materials and obtain the high productivity because of fixed abrasive. The preparation process of fixed abrasive pad (FAP) was described. FALP of K9 glass, mobile panel glass and Si were investigated with fixed 5-10 µm diamond abrasives. The effect on material removal rate (MRR) and surface quality of different materials was studied. The results show that in the same FALP process conditions, Si is the highest MRR and reaches 4428 nm/min, mobile panel glass is inferior to and K9 glass is the lowest. And surface quality of mobile panel glass that surface roughness Sa is 2.10 nm and little and less damages is the best, Si is followed and K9 glass is the worst. So FALP can obtain the higher MRR and reaches several micrometers per minute and the better quality that surface roughness Sa can reach nanometer level for different materials.

Improving the Surface Roughness of a CVD Coated Silicon Carbide Disk by Performing Ductile Regime Single Point Diamond Turning

2008 ◽  
Author(s):  
Deepak Ravindra ◽  
John Patten
Keyword(s):  
Surface Roughness ◽  
Silicon Carbide ◽  
Surface Quality ◽  
Removal Rate ◽  
Single Point ◽  
Extreme Environments ◽  
High Hardness ◽  
Diamond Turning ◽  
Ductile Regime Machining

Silicon carbide (SiC) is one of the advanced engineered ceramics materials designed to operate in extreme environments. One of the main reasons for the choice of this material is due to its excellent electrical, mechanical and optical properties that benefit the semiconductor, MEMS and optoelectronic industry respectively. Manufacture of this material is extremely challenging due to its high hardness, brittle characteristics and poor machinability. Severe fracture can result when trying to machine SiC due to its low fracture toughness. However, from past experience it has been proven that ductile regime machining of silicon carbide is possible. The main goal of the subject research is to improve the surface quality of a chemically vapor deposited (CVD) polycrystalline SiC material to be used in an optics device such as a mirror. Besides improving the surface roughness of the material, the research also emphasized increasing the material removal rate (MRR) and minimizing the diamond tool wear. The surface quality was improved using a Single Point Diamond Turning (SPDT) machining operation from 1158nm to 88nm (Ra) and from 8.49μm to 0.53μm (Rz; peak-to-valley).

Dry WEDM in Improving HS-WEDMed Surface Quality

2008 ◽  
Vol 392-394 ◽  
pp. 624-628 ◽  
Author(s):  
Tong Wang ◽  
Yu Mei Lu ◽  
Shuang Shuang Hao ◽  
Shu Qiang Xie ◽  
Xiao Cun Xu ◽  
...  
Keyword(s):  
Surface Roughness ◽  
Surface Quality ◽  
Material Removal ◽  
High Speed ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Dry Wedm ◽  
Finish Cut ◽  
The Relationship

This paper studies the surface quality of mould steel with high-speed wire electrical discharge machining (WEDM) method, which is conducted in gas to improve the accuracy of finish cut, and compares the surface quality in atmosphere and in emulsion dielectric. Experiment results showed that WEDM in atmosphere offers advantages such as better surface roughness and higher material removal rate. The relationship about winding speed and worktable feed on WEDMed surface quality in semi-finishing cut and finishing cut had been obtained. Morover, a new attemption was successful in applying dry WEDM in multiple cut to improve surface roughness.

Dry WEDM in Improving LS-WEDMed Surface Quality

2008 ◽  
Vol 53-54 ◽  
pp. 387-392 ◽  
Author(s):  
Tong Wang ◽  
Yu Mei Lu ◽  
Shu Qiang Xie ◽  
Shuang Shuang Hao ◽  
H. Zhao
Keyword(s):  
Surface Roughness ◽  
Surface Quality ◽  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Wire Electrical Discharge Machining ◽  
Dry Wedm ◽  
Cut Surface ◽  
Discharge Gap

Utilizing gas as the dielectric instead of dielectric liquid has enabled the development of dry wire electrical discharge machining (dry WEDM) technology for finishing cut. Experiment results showed that Low-Speed WEDM (LS-WEDM) in gas offers advantages such as better straightness, and shorter discharge gap. This paper studies on influence of different gas dielectrics, wire winding speed and pulse duration on the WEDMed surface quality (discharge gap, straightness, surface roughness, removal rate) in finishing. New attempt of applying dry WEDM as the 4th cut had been proved feasible in improving conventional multiple cut surface quality of LS-WEDM.

Effects of High Frequency Vibration on the Surface Quality in Rotary Ultrasonic Machining of Glass BK7

2013 ◽  
Vol 427-429 ◽  
pp. 187-190 ◽  
Author(s):  
Dong Xi Lv ◽  
Yong Jian Tang ◽  
Yan Hua Huang ◽  
Hong Xiang Wang
Keyword(s):  
Surface Roughness ◽  
Brittle Fracture ◽  
Surface Quality ◽  
High Frequency ◽  
Material Removal ◽  
Spindle Speed ◽  
Ultrasonic Machining ◽  
Rotary Ultrasonic Machining ◽  
Machining Processes ◽  
High Frequency Vibration

Both rotary ultrasonic machining (RUM) and conventional grinding (CG) experiments were performed on the glass BK7 specimen to investigate the effects of high frequency vibration on the surface quality. The surface morphologies produced in the two machining processes were assessed and the associated material removal mechanisms were explored. Also, the influence of the spindle speed on the surface roughness was discussed. It was found that the mechanisms of the material removal involved in the RUM process were material pulverization and brittle fracture, while ductile flow and brittle fracture prevailed on the material removal in CG process. The increased spindle speed would reduce the lateral cutting depth of each abrasive, and promote the shielding effects of the lateral cracks generated by the previous abrasive, leading to the reduction of the surface roughness in both RUM and CG processes.

Study on Finishing Cut with Dry WEDM

2006 ◽  
Vol 532-533 ◽  
pp. 273-276 ◽  
Author(s):  
Tong Wang ◽  
Xin Fu Zhang ◽  
Xue Fang Zhao
Keyword(s):  
Surface Roughness ◽  
Surface Quality ◽  
Electrical Discharge ◽  
Material Removal ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Lower Surface ◽  
Wire Electrical Discharge Machining ◽  
Dry Wedm

Utilizing gas as the dielectric instead of dielectric liquid has enabled the development of dry wire electrical discharge machining (WEDM) technology for finishing cut. This paper studies on the surface quality of tool steel with WEDM method, which is conducted in gas to improve the accuracy of finishing cut, and compares the surface quality in atmosphere and in water. Experiment results showed that Low-Speed WEDM in atmosphere offers advantages such as better straightness, lower surface roughness and shorter gap length, but WEDM in atmosphere has poorer material removal rate than conventional WEDM in water. It was also found the removal rate in atmosphere can be improved by increasing the wire winding speed.

Experimental Investigation on Ultrasonic Face Machining of Glass with Free Abrasives

2008 ◽  
Vol 375-376 ◽  
pp. 268-273 ◽  
Author(s):  
Shu You Zheng ◽  
Xi Peng Xu
Keyword(s):  
Surface Roughness ◽  
Material Removal ◽  
Removal Rate ◽  
Static Force ◽  
Ultrasonic Machining ◽  
Rotary Ultrasonic Machining ◽  
Optimal Value ◽  
Video Microscope ◽  
Set Up ◽  
The Given

Serials of ultrasonic face machining experiments were designed and carried out on glass materials with free abrasives. Two different kinds of ultrasonic machining, namely, non-rotary ultrasonic machining (NRUSM) with free abrasives and rotary ultrasonic machining (RUSM) with free abrasives were compared. Two systems were set up to in-process monitor the changes of static forces and frequency respectively. The effects of static force, spindle speed and amplitude of ultrasonic vibration on material removal rate (MRR) and surface roughness were analyzed. The surface of workpieces was also observed by a digital video microscope system. The experimental results indicated that, at the given conditions, there exists an optimal value of static force and amplitude of vibration to obtain the maximum MRR, and RUSM was found to be superior to NRUSM in the MRR, but inversely in surface roughness.

Actively Cooled and Activated Coolant for Grinding Brittle Materials

2008 ◽  
Vol 389-390 ◽  
pp. 338-343 ◽  
Author(s):  
Y. Gao ◽  
J. Xin ◽  
H. Lai
Keyword(s):  
Surface Roughness ◽  
Surface Morphology ◽  
Surface Quality ◽  
Experimental Studies ◽  
Brittle Materials ◽  
Cryogenic Cooling ◽  
Experimental Results ◽  
Cooling Method ◽  
Cooling Methods

An actively cooled and activated cooling approach is proposed and examined in this project in order to deal with the problems associated with methods such as the cryogenic cooling method. It is also aimed to further improve the surface quality of the workpiece after grinding by combining the advantages of the existing cooling methods. Both computational and experimental studies were conducted for grinding the brittle materials with the proposed approach. Optical examinations were used to study the surface morphology. The experimental results show that the surface quality can be improved by up to 23.75% on average in terms of surface roughness Ra. The computational test reveals that the heat can be taken away more effectively by the proposed approach.

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