Werkzeuge der ultraschallunterstützten Bearbeitung*/Modelling of an Actorsystem - Development of a tool for ultrasonic assisted machining with an axial-tangential vibration vector

2018 ◽  
Vol 108 (01-02) ◽  
pp. 53-57
Author(s):  
K. Drewle ◽  
T. Stehle ◽  
H: Möhring
Keyword(s):  
Contact Zone ◽  
Brittle Materials ◽  
Wird Eine ◽  
Alternative Method ◽  
Ultrasonic Assisted ◽  
Ultrasonic Assisted Machining ◽  
Hard And Brittle Materials ◽  
Feed Axis

Die schwingungsunterstützte Bearbeitung hat sich bereits bei der Zerspanung von hartspröden Werkstoffen mit einer einachsigen Schwingung in der Kontaktzone bewährt. Untersuchungen zu schwingungsunterstützten Bohrprozessen beschränken sich bisher auf eine Schwingungserzeugung, die entlang der Vorschubachse ausgerichtet ist. Für alternative Schwingungsrichtungen fehlt in erster Linie die geeignete Aktorik. In diesem Beitrag wird eine alternative Methode zur Erzeugung einer axial-tangentialen Schwingung in der Kontaktzone untersucht.   Ultrasonic assisted machining with uniaxial vibration is a well-proven process for machining hard and brittle materials. Existing investigations of vibration assisted drilling and boring processes so far are limited to an oscillation along the feed axis, which primarily due to nonexistent actuators. This contribution will present investigations into an alternative method for creating axial-tangential vibrations in the tool contact zone.

Spanende Bearbeitung von Faserverbundkunststoffen*/Ultrasonic-assisted machining

2017 ◽  
Vol 107 (09) ◽  
pp. 662-667
Author(s):  
E. Prof. Uhlmann ◽  
G. Christiansen
Keyword(s):  
Ultrasonic Vibration ◽  
Mass Production ◽  
Manufacturing Processes ◽  
Wird Eine ◽  
Structural Components ◽  
Process Forces ◽  
Milling Tool ◽  
Ultrasonic Assisted ◽  
Ultrasonic Assisted Machining ◽  
Increase Productivity

Die spanende Fertigung von faserverstärkten Strukturbauteilen ist technologisch herausfordernd. Der Einsatz neuartiger Fertigungsprozesse, wie die ultraschallunterstützte, roboterbasierte Fräsbearbeitung, kann ein Lösungsansatz für die Steigerung der Produktivität in der Massenfertigung sein. Für diesen Einsatzzweck wird eine Ultraschallschnittstelle zur Einleitung einer Ultraschallschwingung in ein Fräswerkzeug entwickelt und der Einfluss auf die Prozesskräfte untersucht.   The machining of fiber-reinforced structural components is technologically challenging. The use of novel manufacturing processes such as ultrasonic-assisted, robot-based milling is an approach to increase productivity in mass production. To this end, an ultrasonic interface has been developed for inducing ultrasonic vibration into a milling tool. It is primarily investigated how this system impacts the process forces.

Tool Wear and Form Accuracy in Ultrasonic-Assisted Milling of Soda-Lime Glass

2018 ◽  
Vol 786 ◽  
pp. 206-214
Author(s):  
Yasmine El-Taybany ◽  
Mohab Hossam ◽  
Hassan El-Hofy
Keyword(s):  
Tool Wear ◽  
Brittle Materials ◽  
Soda Lime ◽  
Machining Process ◽  
Depth Of Cut ◽  
Soda Lime Glass ◽  
Form Accuracy ◽  
Ultrasonic Assisted ◽  
Hard And Brittle Materials ◽  
Vibration Assistance

Machining of hard and brittle materials is inherently involved with tool wear, which influences the dimensional and form accuracy of the machined product. Ultrasonic-assisted machining process is suitable for hard-to-cut materials such as ceramics, glass, and metal matrix composites, etc. In the current study, the mechanism of tool wear is investigated during ultrasonic-assisted milling of soda-lime glass as one of hard and brittle materials. Ultrasonic-Assisted Milling (UAM) combines the material removal mechanism of grinding and the milling kinematics with ultrasonic assistance. The effect of different process parameters, i.e. feed rate, depth of cut, cutting fluid, and ultrasonic vibration assistance on the tool wear behavior are investigated. Form accuracy of the machined slots is also investigated. The results showed that UAM produces less tool wear than conventional milling (CM). However, CM gives less error in the slot dimensions than UAM.

Influence of Ultrasonic Assistance on Material Removal Mechanism of Hard and Brittle Materials Based on Single-Point Scratch

2011 ◽  
Vol 487 ◽  
pp. 413-418 ◽  
Author(s):  
Feng Jiao ◽  
Bo Zhao
Keyword(s):  
Material Removal ◽  
Single Point ◽  
Brittle Materials ◽  
Shielding Effect ◽  
Depth Of Cut ◽  
Cutting Depth ◽  
Critical Cutting Depth ◽  
Material Hardness ◽  
Ultrasonic Assisted ◽  
Hard And Brittle Materials

In order to deeply study the influence of ultrasonic assistance on material removal characteristics of hard and brittle materials, a series of ultrasonic assisted single-point scratch experiments have been carried out in this paper. Experimental results show that the assisted ultrasonic vibration is benefit to increase the critical cutting depth and enlarge the ductile regime of material removal. The main reason can be explained as the influences of blank cutting phenomenon, the decrease of the normal cutting force under the same depth of cut, the decrease of the material hardness under ultrasonic excitation and the shielding effect of lateral crack.

Probabilistic model of surface layer removal when grinding brittle non-metallic materials

2021 ◽  
Vol 23 (2) ◽  
pp. 6-16
Author(s):  
Sergey Bratan ◽  
◽  
Stanislav Roshchupkin ◽  
Alexander Kharchenko ◽  
Anastasia Chasovitina ◽  
...  
Keyword(s):  
Surface Layer ◽  
Contact Zone ◽  
Probabilistic Model ◽  
Material Removal ◽  
Brittle Materials ◽  
Grinding Wheel ◽  
Metallic Materials ◽  
Deformable Solid ◽  
Metallic Material ◽  
Wide Range

Introduction. The final quality of products is formed during finishing operations, which include the grinding process. It is known that when grinding brittle materials, the cost of grinding work increases significantly. It is possible to reduce the scatter of product quality indicators when grinding brittle materials, as well as to increase the reliability and efficiency of the operation, by choosing the optimal parameters of the technological system based on dynamic models of the process. However, to describe the regularities of the removal of particles of a brittle non-metallic material and the wear of the surface of the grinding wheel in the contact zone, the known models do not allow taking into account the peculiarities of the process in which micro-cutting and brittle chipping of the material are combined. Purpose of the work: to create a new probabilistic model for removing the surface layer when grinding brittle non-metallic materials. The task is to study the laws governing the removal of particles of brittle non-metallic material in the contact zone. In this work, the removal of material in the contact zone as a result of microcutting and brittle chipping is considered as a random event. The research methods are mathematical and physical simulation using the basic provisions of the theory of probability, the laws of distribution of random variables, as well as the theory of cutting and the theory of a deformable solid. Results and discussion. The developed mathematical models make it possible to trace the effect on material removal of the overlap of single cuts on each other when grinding holes in ceramic materials. The proposed dependences show the regularity of stock removal within the arc of contact of the grinding wheel with the workpiece. The considered features of the change in the probability of material removal upon contact of the treated surface with an abrasive tool and the proposed analytical dependences are valid for a wide range of grinding modes, wheel characteristics and a number of other technological factors. The obtained expressions make it possible to find the amount of material removal also for schemes of end, flat and circular external grinding, for which it is necessary to know the amount of removal increment due to brittle fracture during the development of microcracks in the surface layer. One of the ways to determine the magnitude of this increment is to simulate the crack formation process using a computer. The presented results confirm the prospects of the developed approach to simulate the processes of mechanical processing of brittle non-metallic materials.

scholarly journals Extremely Thin Metal Foil Blades as Cutting Tools for Hard and Brittle Materials

2018 ◽  
Vol 221 ◽  
pp. 04006
Author(s):  
Satoshi Sakamoto ◽  
Sanshiro Akaoka ◽  
Masaya Gemma ◽  
Yasuo Kondo ◽  
Kenji Yamaguchi ◽  
...  
Keyword(s):  
Particle Size ◽  
Abrasive Particle ◽  
Brittle Materials ◽  
Groove Depth ◽  
Thin Metal ◽  
Metal Foil ◽  
Machining Time ◽  
Blade Thickness ◽  
Hard And Brittle Materials ◽  
Thin Metal Foil

The manufacturing costs of semiconductor products such as silicon wafers can be reduced by decreasing the kerf loss. In addition, a decrease in the kerf loss leads to an effective utilization of rare materials, which is environmentally beneficial from the viewpoint of saving resources. This study aims to reduce the kerf loss during slicing hard and brittle materials. Therefore, the possibility of using an extremely thin metal foil blade instead of a wire tool in slicing was examined. Initially, grooving characteristics using a metal foil blade (thickness: 50 μm or less) was investigated. The main conclusions are that grooving with a metal foil blade is possible and kerf loss can be reduced. The groove depth tends to increase as the machining time and particle size of abrasives increase. The groove width is smaller when a thin metal foil blade is used and vice versa. However, if the abrasive particle size is too large, grooving becomes impossible. Since the wear of metal foil blade increases with an increase in the particle size of the abrasive, it is necessary to use an abrasive with a particle size that is suitable for the thickness of the metal foil blade.

Improving Productivity in an Ultrasonic-Assisted Drilling Vertical Machining Center

2018 ◽  
Vol 140 (6) ◽  
Author(s):  
M. A. Moghaddas ◽  
M. A. Short ◽  
N. R. Wiley ◽  
A. Y. Yi ◽  
K. F. Graff
Keyword(s):  
Ultrasonic Vibrations ◽  
Machining Processes ◽  
Machining Center ◽  
Ultrasonic Drilling ◽  
Standard Tool ◽  
Ultrasonic Assisted ◽  
Ultrasonic Assisted Machining ◽  
Conventional Machine ◽  
Solid Foundation ◽  
Sufficient Strength

Ultrasonic-assisted machining, which is the application of ultrasonic vibrations to standard or “conventional” machine tools for processes such as drilling, milling, and turning, is a rapidly developing technology aimed at increasing the productivity of machining processes. While a solid foundation is being established through laboratory-based research studies, typically these processes have not yet progressed to fulfill the demanding requirements of the factory floor. The objective of the current work is to transition the ultrasonic-assisted drilling (UAD) process from the laboratory to a production system compatible with automated machining systems. This work details the design and development of an ultrasonic drilling module that has sufficient strength, stiffness, and accuracy for production demands, while maintaining powerful levels of ultrasonic vibrations that result in lowered drilling forces and faster feed rates. In addition, this work will review prior work in UAD, including the development of a module based on a vibration-isolating case using a standard tool holder. Performance of the system is shown to provide thrust force reductions, while maintaining or improving surface finish and drilling accuracy. The results from drilling several materials are presented.

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