An Experimental Study on Processing Performance of Rotary Ultrasonic Drilling of K9 Glass

2011 ◽  
Vol 230-232 ◽  
pp. 221-225 ◽  
Author(s):  
Cheng Long Zhang ◽  
Ping Fa Feng ◽  
Zhi Jun Wu ◽  
Ding Wen Yu
Keyword(s):  
Surface Roughness ◽  
Cutting Force ◽  
Diamond Particle ◽  
Machining Process ◽  
Cutting Depth ◽  
Ultrasonic Drilling ◽  
Cutting Length ◽  
Cutting Velocity ◽  
Rotary Ultrasonic Drilling ◽  
K9 Glass

Rotary ultrasonic machining process, regarded as one of the effective processing methods for hard-brittle materials, is introduced into drilling K9 glass in this paper. The effective cutting velocity, cutting depth, and cutting length of single diamond particle are determined by analyzing the kinematics characteristic of diamond tool in rotary ultrasonic drilling (RUD). Experiments are conducted to study the influences of process variables (spindle speed, feedrate) on cutting force, chipping size, and surface roughness in RUD. As comparison study, the processing performances between RUD and diamond drilling are also discussed. The experimental results show that the RUD process can significantly reduce cutting force and the value of chippings size, which inferred that RUD process can improve machining efficiency and make the machining cost lower. It is also concluded that the effective cutting depth of diamond particles is the main factor for surface roughness in RUD of K9 glass.

Theoretical and Experimental Research on the Features of Cutting Force in Rotary Ultrasonic Face Milling of K9 Glass

2012 ◽  
Vol 157-158 ◽  
pp. 1674-1679 ◽  
Author(s):  
Cheng Long Zhang ◽  
Ping Fa Feng ◽  
Jian Fu Zhang ◽  
Zhi Jun Wu ◽  
Ding Wen Yu
Keyword(s):  
Cutting Force ◽  
Material Removal ◽  
Diamond Particle ◽  
Process Variable ◽  
Face Milling ◽  
Process Conditions ◽  
Cutting Depth ◽  
Surface Machining ◽  
Cutting Length ◽  
K9 Glass

This study introduces rotary ultrasonic face milling (RUFM) process into flat surface machining of K9 glass. The effective cutting velocity, and cutting length of single diamond particle were presented in RUFM. The model of material removal for RUFM was developed through examining indentation fracture mechanics theory and material removal characteristics of brittle materials, and analyzing kinematics properties of diamond grits in RUFM. With a view of comparative researches, the cutting force of RUFM and diamond milling of K9 glass are compared. The experimental results tell that the relationship between the cutting depth (dc) and the ultrasonic amplitude (A) of the cutter has remarkable effects on cutting force, which was also discussed in the kinematic characteristics analysis section. The results also show that RUFM process can significantly reduce cutting force and the effects of process variable changes on cutting force in RUFM are weaker as dc is smaller than A. However, the reduction trends of the cutting forces in RUFM are very small and even increased in some process conditions, as dc is larger than A. It suggests that the cutting depth should be smaller than the ultrasonic amplitude of the cutter with RUFM process to obtain better processing performance.

A Mathematical Model for Predicting Cutting Force in Rotary Ultrasonic Drilling

2012 ◽  
Vol 433-440 ◽  
pp. 2034-2041 ◽  
Author(s):  
Cheng Long Zhang ◽  
Ping Fa Feng ◽  
Zhi Jun Wu ◽  
Ding Wen Yu
Keyword(s):  
Mathematical Model ◽  
Cutting Force ◽  
Machining Process ◽  
Computation Method ◽  
Force Model ◽  
Machining Parameters ◽  
Ultrasonic Machining ◽  
Rotary Ultrasonic Machining ◽  
Ultrasonic Drilling ◽  
Rotary Ultrasonic Drilling

Rotary ultrasonic machining is a hybrid machining process that combines diamond grinding and ultrasonic machining. The mathematical predictive material removal rate models have been developed in rotary ultrasonic machining with a constant pressure. However, there is no report on mathematical predictive cutting force model in rotary ultrasonic drilling at a constant feedrate presently. Since cutting force can not only reflect the processing state, but also affect the machined surface quality, it is necessary to develop a mathematical model for predicting cutting force which can forecast the machining results. This paper presents a mathematical model to predict the cutting force in rotary ultrasonic machining. On the basis of this model, the relations between cutting force and controllable machining parameters are researched by numerical computation method. This paper also researches the influences of spindle speed and feedrate on cutting force by experiments. The results observed through the experiments agree well with the relations generated from the mathematical model, which verify the developed model.

Experimental Investigation of Rotary Ultrasonic Face Milling of K9 Glass

2011 ◽  
Vol 230-232 ◽  
pp. 644-648 ◽  
Author(s):  
Cheng Long Zhang ◽  
Ping Fa Feng ◽  
Shu You Zheng ◽  
Zhi Jun Wu ◽  
Ding Wen Yu
Keyword(s):  
Surface Roughness ◽  
Cutting Force ◽  
Mechanical Characteristics ◽  
Flat Surface ◽  
Face Milling ◽  
Cutting Depth ◽  
Excellent Performance ◽  
First Time ◽  
K9 Glass ◽  
Diamond Milling

K9 glass is regarded as one of the most difficult-to-machine materials due to its mechanical characteristics, which is known as an excellent performance optical material. In this paper, rotary ultrasonic face milling (RUFM) process is introduced into machining flat surface of K9 glass using right-angle diamond cutter for the first time. It studies the influence of process variables (spindle speed, feedrate, cutting depth, and cutting width) on cutting force and surface roughness through the single-factor experiments. The cutting force is measured by a KISTLER dynamometer, and the surface roughness is measured by a talysurf. The investigation also includes a comparison between RUFM and diamond milling. The experimental results tell that the RUFM process can significantly reduce cutting force, which inferred that RUFM can have less tool wear and longer tool life. It also shows that the surface roughness in RUFM of K9 glass is slightly higher than that obtained in diamond milling.

Surface Roughness and Cutting Force Components Evaluation in Hard Turning by Differently Shaped Cutting Tools

2016 ◽  
Vol 862 ◽  
pp. 26-32 ◽  
Author(s):  
Michaela Samardžiová
Keyword(s):  
Surface Roughness ◽  
Cutting Force ◽  
Hard Turning ◽  
Cutting Tool ◽  
Single Point ◽  
Machining Process ◽  
Tool Geometry ◽  
Machined Surface ◽  
Cutting Force Components ◽  
Force Components

There is a difference in machining by the cutting tool with defined geometry and undefined geometry. That is one of the reasons of implementation of hard turning into the machining process. In current manufacturing processes is hard turning many times used as a fine finish operation. It has many advantages – machining by single point cutting tool, high productivity, flexibility, ability to produce parts with complex shapes at one clamping. Very important is to solve machined surface quality. There is a possibility to use wiper geometry in hard turning process to achieve 3 – 4 times lower surface roughness values. Cutting parameters influence cutting process as well as cutting tool geometry. It is necessary to take into consideration cutting force components as well. Issue of the use of wiper geometry has been still insufficiently researched.

scholarly journals Influence of Ultrasonic Vibration-Assisted Ball-End Milling on the Cutting Performance of AZ31B Magnesium Alloy

2020 ◽  
Vol 9 (4) ◽  
pp. 271-276
Keyword(s):  
Surface Roughness ◽  
Cutting Force ◽  
Ultrasonic Vibration ◽  
Biomedical Applications ◽  
End Milling ◽  
Cutting Temperature ◽  
Cutting Performance ◽  
Machining Process ◽  
Dry Conditions ◽  
Good Biocompatibility

Magnesium alloys have a tremendous possibility for biomedical applications due to their good biocompatibility, integrity and degradability, but their low ignition temperature and easy corrosive property restrict the machining process for potential biomedical applications. In this research, ultrasonic vibration-assisted ball milling (UVABM) for AZ31B is investigated to improve the cutting performance and get specific surface morphology in dry conditions. Cutting force and cutting temperatures are measured during UVABM. Surface roughness is measured with a white light interferometer after UVABM. The experimental results show cutting force and cutting temperature reduce due to ultrasonic vibration, and surface roughness decreases by 34.92%, compared with that got from traditional milling, which indicates UVABM is suitable to process AZ31B for potential biomedical applications.

Design of a Novel Air Bearing Workbench for Rotary Ultrasonic Drilling of Advanced Ceramics

2012 ◽  
Vol 134 (9) ◽  
Author(s):  
Liping Liu ◽  
Bin Lin ◽  
Fengzhou Fang
Keyword(s):  
Finite Element Method ◽  
Finite Element ◽  
Bearing Capacity ◽  
Cutting Force ◽  
Air Bearing ◽  
The Novel ◽  
Advanced Ceramics ◽  
Air Damping ◽  
Ultrasonic Drilling ◽  
Rotary Ultrasonic Drilling

A novel air bearing workbench used in rotary ultrasonic drilling of advanced ceramics was designed to constantly and sensitively control the cutting force. Compared with traditional feed systems, the novel air bearing workbench features an aerostatic guide and a pneumatic actuator, so that it only overcomes the air damping when the cutting force is balanced. Thus, it can sensitively and constantly control the cutting force for rotary ultrasonic drilling of advanced ceramics. The aerostatic guide, which determines the eccentric bearing capacity and stiffness of the workbench, is the most important part. The forces applied on the aerostatic guide faces were analyzed to calculate the bearing capacity and stiffness of the workbench using varying gas film thicknesses with finite element method (FEM). Based on the result of the analysis, the best gas film thickness of the aerostatic guide was designed to be 30 μm. The real eccentric bearing capacity and stiffness of the workbench were measured. The error between experimental results and the FEM results was within 12%.

scholarly journals Experimental study on cutting parameters and machining paths of SiCp/Al composite thin-walled workpieces

2020 ◽  
Vol 29 ◽  
pp. 2633366X2094252
Author(s):  
Yunan Liu ◽  
Shutao Huang ◽  
Keru Jiao ◽  
Lifu Xu
Keyword(s):  
Cutting Force ◽  
Volume Fraction ◽  
Cutting Speed ◽  
Aluminum Matrix ◽  
Machining Process ◽  
Cutting Depth ◽  
Processing Efficiency ◽  
Al Composite ◽  
Edge Defects ◽  
Thin Walled

Thin-walled workpieces of silicon carbide particle-reinforced aluminum matrix (SiCp/Al) composites with outstanding properties have been widely applied in many fields, such as automobile, weapons, and aerospace. However, the thin-walled workpieces exhibit poor rigidity, large yield ratio, and easily deform under the cutting force and cutting heat during the machining process. Herein, in order to improve the processing efficiency and precision of higher volume fraction SiCp/Al composite thin-walled workpieces, the influence of different high-speed milling parameters and machining paths on the edge defects is analyzed. The results reveal that the cutting force initially increased and then decreased with the cutting speed. Besides, the cutting force steadily increased with radial cutting depth and feed per tooth, but the influence of feed per tooth is less than radial cutting depth. After up-milling cut-in and cut-out processing and down-milling cut-out processing, the cut-in end of the workpiece exhibited higher breakage and obvious edge defects. However, the workpiece edges remained intact after down-milling cut-in processing. In conclusion, a higher cutting speed, a smaller radial cutting depth, and moderate feed per tooth are required to decrease the cutting force during the milling of SiCp/Al composite thin-walled workpiece. Furthermore, down-milling cut-in processing mode can reduce the edge defects and improve the processing efficiency and precision of the workpiece.

Research on the Cutting Fluid Effect on Cutting Force and Surface Roughness in Rotor Milling

2012 ◽  
Vol 723 ◽  
pp. 50-55
Author(s):  
Jian Lu Wang ◽  
Liang Liang Wu ◽  
Jun Zhang ◽  
Wan Hua Zhao ◽  
Yi Fei Jiang ◽  
...  
Keyword(s):  
Surface Roughness ◽  
Cutting Force ◽  
Design Method ◽  
Uniform Design ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Cutting Fluid ◽  
Cutting Depth ◽  
Multivariable Regression ◽  
Uniform Design Method

A series of milling experiments with and without cutting fluid, arranged by uniform design method, were carried out on rotor material. The influence of cutting fluid on cutting force and surface roughness was explored and compared for the two kinds of conditions. The associated model was established between cutting force & surface roughness and cutting parameters according to the linear multivariable regression method. The results show that the cutting force deceases with the increase of the cutting speed or with the decrease of the feed per tooth and the cutting depth. Cutting fluid has little effect on cutting force, and for surface roughness, the influence of cutting fluid is uncertain.

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