A Study on Surface Generation along Nominal Cutting Direction in Elliptical Vibration Cutting

2011 ◽  
Vol 314-316 ◽  
pp. 1851-1856 ◽  
Author(s):  
Xin Quan Zhang ◽  
A. Senthil Kumar ◽  
Mustafizur Rahman
Keyword(s):  
Cutting Speed ◽  
Surface Generation ◽  
Machining Parameters ◽  
Generation Process ◽  
Promising Technique ◽  
Machined Surface ◽  
Elliptical Vibration Cutting ◽  
Vibration Cutting ◽  
Elliptical Vibration ◽  
Cutting Direction

The elliptical vibration cutting (EVC) technique has been found to be a promising technique for ultraprecision machining of various materials. Researchers have proved that the EVC technique prevails over both conventional cutting and 1D vibration cutting techniques in most aspects in terms of cutting performances. However, during the EVC process, vibration marks or cusps are generated by the elliptical vibration locus and can result in an increase in the overall roughness of machined surface, which is undesirable for achieving high-quality mirror surface. Although researchers have developed a calculation method for the height of the cusps, only the effects of vibration frequency on surface generation were studied, and the effects of the other vibration and machining parameters have not been investigated in detail by previous researchers. Hence, in the present study, in order to deeply understand surface generation process along nominal cutting direction under the EVC technique, which is critical for its performance improvement and application, an experimental study comprising a series of grooving tests was carried out. The effects of nominal cutting speed on the surface generation at two different thrust-directional vibration amplitudes are investigated. Analysis is given for the comparison between the theoretical and experimental roughness values, showing that there exists a critical nominal cutting speed, below which the measured roughness value is quite small and the vibration marks are almost undetectable.

Modeling of the Effect of Machining Parameters on Maximum Thickness of Cut in Ultrasonic Elliptical Vibration Cutting

2011 ◽  
Vol 133 (1) ◽  
Author(s):  
Chandra Nath ◽  
Mustafizur Rahman ◽  
Ken Soon Neo
Keyword(s):  
Brittle Materials ◽  
Cutting Speed ◽  
Role Playing ◽  
Machining Parameters ◽  
Elliptical Vibration Cutting ◽  
Tool Vibration ◽  
Vibration Cutting ◽  
Elliptical Vibration ◽  
Hard And Brittle Materials ◽  
Ultrasonic Elliptical Vibration

In recent years, the ultrasonic elliptical vibration cutting (UEVC) technique has been found to be an efficient method for the ultraprecision machining of hard and brittle materials. During the machining at a given nominal depth of cut (DOC), the UEVC technique, because of its inherent mechanism, effectively reduces the thickness of cut (TOC) of the workpiece material through overlapping vibration cycles. For the ductile machining of hard and brittle materials, this TOC plays a critical role. However, the relationships between the nominal DOC, the TOC, and the relevant machining parameters have not yet been studied. In this study, the role playing machining parameters for the TOC are firstly investigated and then theoretical relations are developed for predicting the maximum TOC (TOCm) with respect to the relevant machining parameters. It is found that four machining parameters, namely, workpiece cutting speed, tool vibration frequency, and tangential and thrust directional vibration amplitudes, influence the TOCm. If the speed ratio (ratio of the workpiece cutting speed to the maximum tool vibration speed in the tangential direction) is within a critical value 0.12837, then a reduced TOCm can be obtained. It is also realized that if the TOCm can be kept lower than the critical DOC (DOCcr), then ductile finishing of brittle materials can be achieved. The above phenomenon has been substantiated by experimental findings while machining a hard and brittle material, sintered tungsten carbide. The findings suggest that the same concept can be applied for the ductile cutting of other hard and brittle materials.

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.

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.

High Frequency Ultrasonic Elliptical Vibration Turning Studty for Weak Rigidity Precision Workpiece

2011 ◽  
Vol 467-469 ◽  
pp. 236-240 ◽  
Author(s):  
Wen Li ◽  
De Yuan Zhang
Keyword(s):  
Surface Roughness ◽  
High Frequency ◽  
Critical Speed ◽  
Machining Efficiency ◽  
Elliptical Vibration Cutting ◽  
Vibration Cutting ◽  
Elliptical Vibration ◽  
Forming Accuracy ◽  
Ultrasonic Elliptical Vibration ◽  
Cutting Direction

Based on analysis of the micro-surface and kinematical formulas of elliptical vibration cutting(EVC), the paper presents that frequency and amplitude of vibration parameter affect surface roughness, forming accuracy and machining efficiency of weak rigidity workpiece: increase vibration frequency are result in lower vibration cutting duty cycle , lower cutting force, advancer critical speed, so advance forming accuracy and machining efficiency; decrease amplitude are result in reduce the height of vibration ripples in cutting direction , so improve surface roughness. Experiences of cutting the weak rigidity workpiece by the designed double bending hybrid vibration high transducer, verified that the high frequency elliptical vibration cutting are proved more conducive to machining weak rigidity workpiece.

A novel three-dimensional elliptical vibration cutting device based on the freedom and constraint topologies theory

2018 ◽  
Vol 233 (3) ◽  
pp. 675-685 ◽  
Author(s):  
Sheng Lin ◽  
Xi Kong ◽  
Chun Wang ◽  
Yun Zhai ◽  
Liang Yang
Keyword(s):  
Design Theory ◽  
Compliant Mechanism ◽  
Three Dimensional ◽  
Cutting Speed ◽  
Elliptical Vibration Cutting ◽  
Vibration Cutting ◽  
Elliptical Vibration ◽  
The Common ◽  
Constraint Topologies ◽  
The Relationship

Aiming at the issue of the lack of the design theory for the three-dimensional elliptical vibration cutting device, a compliant mechanism with two rotations and one translation is synthesized based on the theory of freedom and constraint topologies. And a three-dimensional elliptical vibration cutting device is proposed on the basis of the compliant mechanism. The relationship between the critical speed and the length of the tool bar is analyzed. Simulation is conducted to analyze the influence of parameters on the output ellipse. Experiments are conducted to verify the validity of the elliptical vibration cutting device. The relationship between the roughness and the cutting speed is obtained. Experiments with different driving frequencies are conducted without the change of other parameters. Results show that the proposed compliant mechanism is feasible for the elliptical vibration cutting device. Compared with the common cutting, the new elliptical vibration cutting device has a better performance in the processing effect. This provides an important reference for design of the elliptical vibration cutting device.

FE Analysis of One-Directional and Elliptical Vibration Cutting Processes

2010 ◽  
Vol 4 (3) ◽  
pp. 252-258 ◽  
Author(s):  
Saeid Amini ◽  
◽  
Eiji Shamoto ◽  
Norikazu Suzuki ◽  
Mohammad Javad Nategh ◽  
...  
Keyword(s):  
Cutting Tool ◽  
Fe Analysis ◽  
Speed Ratio ◽  
Fe Model ◽  
Elliptical Vibration Cutting ◽  
Vibration Cutting ◽  
Elliptical Vibration ◽  
The One ◽  
Cutting Processes ◽  
Cutting Direction

Processes of one-directional vibration cutting, elliptical vibration cutting and conventional cutting are modelled by using MSC-Marc FEM software in the present study. The vibration is assumed to be applied to a rigid cutting tool in the cutting direction for the one-directional vibration cutting and in the cutting and thrust directions for the elliptical vibration cutting. Then, the cutting forces and the stresses generated within the workpiece during the abovementioned processes are estimated by applying the developed FE model, and their cutting mechanics are discussed. Influence of various process parameters such as speed ratio, amplitudes and phase difference is subsequently investigated. The simulated results are also compared with some experimental data published in the literature.

Optimization of Ultrasonic Elliptical Vibration Cutting Parameters Based on Response Surface Method

2020 ◽  
Vol 13 ◽  
Author(s):  
Wei Zhang ◽  
Maohua Xiao ◽  
Liang Zhang
Keyword(s):  
Response Surface ◽  
Response Surface Method ◽  
Cutting Parameters ◽  
Cutting Process ◽  
Machining Parameters ◽  
Elliptical Vibration Cutting ◽  
Vibration Cutting ◽  
Elliptical Vibration ◽  
Surface Method ◽  
Optimal Cutting Parameters

Background: Problems, such as severe hardening and poor processing quality, are present in the cutting process of difficult-to-machine materials. Objective: To investigate and optimize the machining parameters of 630 stainless steel by using an independently designed 28-KHz double-excitation elliptical vibration cutting process. Methods: Using the AdvantEdge platform and response surface method, the effects of the cutting speed Results: Results show that the error of the experimental results relative to the predicted ones under the optimized cutting parameter combination is less than 9%. Conclusion: Based on the response surface method, the optimal cutting parameters are obtained, and the cutting force and cutting temperature are at a lower level. The findings indicate the feasibility of the optimized machining parameters and provide a reference for the selection of cutting parameters and the publish of patents and when ultrasonic vibration is used to cut difficult-to-machine materials.

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.

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