Research on Power Ultrasonic Vibration Honing of Sintered Nd-Fe-B

2012 ◽  
Vol 472-475 ◽  
pp. 962-967 ◽  
Author(s):  
Yun Peng Shao ◽  
Xi Jing Zhu ◽  
Ai Ling Wang ◽  
Zhen Liu
Keyword(s):  
Ultrasonic Vibration ◽  
Material Removal ◽  
Removal Rate ◽  
Processing Parameters ◽  
Machining Process ◽  
Processing Efficiency ◽  
Workpiece Surface ◽  
Optimal Processing ◽  
Orthogonal Experiments ◽  
Power Ultrasonic

The technology of power ultrasonic vibration honing was used for the brittle hard sintered Nd-Fe-B materials in this paper. The feasibility and correctness of machining process was analyzed through experiments. Compared normal process result with orthogonal experiments, it was better to use power ultrasonic vibration honing to obtain parts with less surface roughness and higher material removal rate, and also the optimal processing parameters can be conduct. Therefore, the power ultrasonic vibration honing can be used to improve workpiece surface quality, as well as processing efficiency, precision, which is an effective method for precise machining of sintered Nd-Fe-B materials.

Optimization of μEDM process assisted with rotating magnetic pulling force and ultrasonic vibration

2021 ◽  
pp. 095440892098440
Author(s):  
Gurpreet Singh ◽  
DR Prajapati ◽  
PS Satsangi
Keyword(s):  
Ultrasonic Vibration ◽  
Material Removal Rate ◽  
Electrical Discharge ◽  
Material Removal ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Machining Process ◽  
Micro Electrical Discharge Machining ◽  
Pulling Force ◽  
Tool Rotation

The micro-electrical discharge machining process is hindered by low material removal rate and low surface quality, which bound its capability. The assistance of ultrasonic vibration and magnetic pulling force in micro-electrical discharge machining helps to overcome this limitation and increase the stability of the machining process. In the present research, an attempt has been made on Taguchi based GRA optimization for µEDM assisted with ultrasonic vibration and magnetic pulling force while µEDM of SKD-5 die steel with the tubular copper electrode. The process parameters such as ultrasonic vibration, magnetic pulling force, tool rotation, energy and feed rate have been chosen as process variables. Material removal rate and taper of the feature have been selected as response measures. From the experimental study, it has been found that response output measures have been significantly improved by 18% as compared to non assisted µEDM. The best optimal combination of input parameters for improved performance measures were recorded as machining with ultrasonic vibration (U1), 0.25 kgf of magnetic pulling force (M1), 600 rpm of tool rotation (R2), 3.38 mJ of energy (E3) and 1.5 mm/min of Tool feed rate (F3). The confirmation trail was also carried out for the validation of the results attained by Grey Relational Analysis and confirmed that there is a substantial improvement with both assistance applied simultaneously.

Investigation into Chemo-Mechanical Fixed Abrasive Polishing of Fused Silica with the Assistance of Ultrasonic Vibration

2012 ◽  
Vol 523-524 ◽  
pp. 155-160 ◽  
Author(s):  
Ya Guo Li ◽  
Yong Bo Wu ◽  
Li Bo Zhou ◽  
Hui Ru Guo ◽  
Jian Guo Cao ◽  
...  
Keyword(s):  
Surface Roughness ◽  
Ultrasonic Vibration ◽  
Material Removal Rate ◽  
Material Removal ◽  
Optical Glass ◽  
Removal Rate ◽  
Fused Silica ◽  
Processing Efficiency ◽  
Machined Surface ◽  
Fixed Abrasive

Ultrasonic vibration assisted processing is well known for the improvement in machined surface quality and processing efficiency due to the reduced forces and tribology-generated heating when grinding hard-brittle materials. We transplanted this philosophy to chemo-mechanical fixed abrasive polishing of optical glass, namely fused silica, in an attempt to improve surface roughness and/or material removal rate. Experiments were conducted to elucidate the fundamental characteristics of chemo-mechanical fixed abrasive polishing of fused silica in the presence and absence of ultrasonic vibration on a setup with an in-house built gadget. The experimental results show that ultrasonic vibration assisted chemo-mechanical fixed abrasive polishing can yield increased material removal rate while maintaining the surface roughness of manufactured optics compared to conventional fixed abrasive polishing without ultrasonic vibration. The mechanism of material removal in fixed abrasive polishing was also delved. We found that the glass material is removed through the synergic effects of chemical and mechanical actions between abrasives and glass and the resultant grinding swarf contains ample Si element as well as Ce element, standing in stark contrast to the polisher that contains abundant Ce element and minor Si element.

Electrochemical Finishing with an Electrode Vibrated with Biaxial Ultrasonic Transducer

2008 ◽  
Vol 389-390 ◽  
pp. 289-294
Author(s):  
Manabu Iwai ◽  
Wen Qiu Wei ◽  
Shinichi Ninomiya ◽  
Sadao Sano ◽  
Tetsutaro Uematsu ◽  
...  
Keyword(s):  
Ultrasonic Vibration ◽  
Material Removal ◽  
Vibration Mode ◽  
Removal Rate ◽  
Tap Water ◽  
Ultrasonic Transducer ◽  
Vibration Modes ◽  
Bending Vibration ◽  
Workpiece Surface ◽  
Electrochemical Finishing

In order to realize electrochemical finishing in tap water, an ultrasonic vibration using a transducer enabling three kinds of vibration modes, i.e., axial, bending, and complex, was given to the electrode. During the test finishing, it was observed that with electrode without ultrasonic vibration, the workpiece surface was simply covered with the rust. On the contrary, by applying the ultrasonic vibration of bending vibration mode or complex vibration mode with an appropriate amplitude, the material removal rate was increased and the surface roughness was improved.

Development of a New BCB ELID Lapping Process

2010 ◽  
Vol 154-155 ◽  
pp. 1739-1743
Author(s):  
Wei Li ◽  
Qian Jun Tian
Keyword(s):  
Surface Roughness ◽  
Surface Quality ◽  
Material Removal Rate ◽  
Material Removal ◽  
Removal Rate ◽  
Surface Condition ◽  
Machining Process ◽  
Wheel Surface ◽  
Abrasive Wheel ◽  
Workpiece Surface

In this paper, the mechanism of Electrolysis In-process Dressing (ELID) lapping process using new BCB (bamboo charcoal bonded) abrasive wheel is researched. Some experiments of machining for silicon wafers were carried out for exploring the effect of some machining process parameters on material removal rate and surface roughness. Experiments show that: Material removal rate and machined workpiece surface roughness are increased with increase of the lapping wheel’s rotation speed and processing loading; The machined workpiece surface quality is affected with the lapping wheel surface condition, due to the abrasives are trued by electrolysis dressing in the lapping process, therefore the BCB lapping wheel always keeps better machining condition to obtain excellent machined workpiece surface quality efficiently.

Modeling of Material Removal Rate in Two-Dimensional Ultrasonic Grinding Complex Ceramics

2007 ◽  
Vol 359-360 ◽  
pp. 431-435
Author(s):  
Guo Fu Gao ◽  
Bo Zhao ◽  
Qing Hua Kong ◽  
Chuan Shao Liu
Keyword(s):  
Ultrasonic Vibration ◽  
Material Removal Rate ◽  
Material Removal ◽  
Removal Rate ◽  
Brittle Materials ◽  
Machining Process ◽  
Machining Parameters ◽  
Two Dimensional ◽  
Vibration Assistance ◽  
Micro Indentation

Based on the machining pattern, mechanics of material removal and theory of micro-indentation, in previous studies the models of material removal rate of hard-brittle materials was discussed through the relatively influencing factors of machining parameters from various aspects, reflecting the research advances on mechanics of material removal of hard-brittle materials. However, those models of material removal rate have limitations, which results from impercipient theory of fracture of new kinks of materials, randomicity of practical machining process, inappropriate assumptions and simplification of the machining conditions and so on. In this work firstly, previous models of material removal rate of hard-brittle materials machining with ultrasonic assistance were reviewed briefly. Subsequently, the models of material removal rate of complex ceramics machining with two-dimensional ultrasonic vibration assistance were established based on fracture theory of micro- indentation in fracture regime and plastic removal mechanics in ductile regime respectively. The material removal rate is affected not only by the properties of material and machining parameters, but also by the character of grinding wheel and parameters of ultrasonic vibration.

Schruppfräsbearbeitung von Verdichterscheiben/Milling of compressor disk - Identification of a cutting material and coating combination for high process reliability

2017 ◽  
Vol 107 (09) ◽  
pp. 674-680
Author(s):  
E. Prof. Abele ◽  
C. Hasenfratz ◽  
C. Praetzas ◽  
G. M. Schüler ◽  
C. Stark ◽  
...  
Keyword(s):  
Material Removal Rate ◽  
Material Removal ◽  
Removal Rate ◽  
Manufacturing Technology ◽  
Machining Process ◽  
Complex Task ◽  
Eine Hohe ◽  
Process Reliability ◽  
Rough Milling ◽  
Compressor Disk

Die Herstellung von Verdichterscheiben stellt hohe Ansprüche an die Fertigungstechnik. Neue, schwer zu zerspanende Materialien und Integralkonstruktionen erzeugen eine hohe Komplexität bei der Ausführung. Das Projekt „SchwerSpan“ stellt sich dieser Herausforderung und entwickelt einen Prozess zur Schruppfräsbearbeitung von Verdichterscheiben. Ziel des Projekts ist eine Reduktion der Werkzeugkosten bei erhöhtem Zeitspanvolumen.   The production of compressor disks places high demands on the manufacturing technology. A very complex task is created by new difficult-to-cut materials and integral components. The project “SchwerSpan” is taking on this task by developing a machining process for rough milling in the production of compressor disks. The aim of the process is to reduce the tool costs by increasing material removal rate.

Experimental Study of Machining of Shape Memory Alloys Using Dry Micro Electrical Discharge Machining Process

2018 ◽  
Author(s):  
Sagil James ◽  
Sharadkumar Kakadiya
Keyword(s):  
Shape Memory Alloys ◽  
Shape Memory ◽  
Electrical Discharge ◽  
Material Removal ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Dielectric Medium ◽  
Machining Process ◽  
Machining Processes ◽  
Micro Electrical Discharge Machining

Shape Memory Alloys are smart materials that tend to remember and return to its original shape when subjected to deformation. These materials find numerous applications in robotics, automotive and biomedical industries. Micromachining of SMAs is often a considerable challenge using conventional machining processes. Micro-Electrical Discharge Machining is a combination of thermal and electrical processes, which can machine any electrically conductive material at micron scale independent of its hardness. It employs dielectric medium such as hydrocarbon oils, deionized water, and kerosene. Using liquid dielectrics has adverse effects on the machined surface causing cracking, white layer deposition, and irregular surface finish. These limitations can be minimized by using a dry dielectric medium such as air or nitrogen gas. This research involves the experimental study of micromachining of Shape Memory Alloys using dry Micro-Electrical Discharge Machining process. The study considers the effect of critical process parameters including discharge voltage and discharge current on the material removal rate and the tool wear rate. A comparison study is performed between the Micro-Electrical Discharge Machining process with using the liquid as well as air as the dielectric medium. In this study, microcavities are successfully machined on shape memory alloys using dry Micro-Electrical Discharge Machining process. The study found that the dry Micro-Electrical Discharge Machining produces a comparatively better surface finish, has lower tool wear and lesser material removal rate compared to the process using the liquid as the dielectric medium. The results of this research could extend the industrial applications of Micro Electrical Discharge Machining processes.

INVESTIGATION OF SINGLE-POINT DRESSING OVERLAP RATIO AND DIAMOND-ROLL DRESSING INTERFERENCE ANGLE ON SURFACE ROUGHNESS IN GRINDING

2010 ◽  
Vol 34 (2) ◽  
pp. 295-308 ◽  
Author(s):  
Akram Saad ◽  
Robert Bauer ◽  
Andrew Warkentin
Keyword(s):  
Surface Roughness ◽  
Material Removal Rate ◽  
Empirical Model ◽  
Material Removal ◽  
Removal Rate ◽  
Single Point ◽  
Experimental Conditions ◽  
Workpiece Surface ◽  
Different Depths ◽  
Overlap Ratio

This paper investigates the effect of both single-point and diamond-roll dressing techniques on the workpiece surface roughness in grinding. Two empirical surface roughness models are studied – one that incorporates single-point dressing parameters, and another that incorporates diamond-roll dressing parameters. For the experimental conditions used in this research, the corresponding empirical model coefficients are found to have a linear relationship with the inverse of the overlap ratio for single-point dressing and the interference angle for diamond-roll dressing. The resulting workpiece surface roughness models are then experimentally validated for different depths of cut, workpiece speeds and dressing conditions. In addition, the models are used to derive a relationship between overlap ratio for single-point dressing, and interference angle for diamond-roll dressing such that both dressing techniques produce a similar surface finish for a given material removal rate.

A Comparison of Generator Mode on the Performance of Finish EDM of AISI P20 Tool Steel

2004 ◽  
Author(s):  
Fred L. Amorim
Keyword(s):  
Tool Steel ◽  
Process Parameters ◽  
Material Removal ◽  
Removal Rate ◽  
Technical Information ◽  
Relaxation Mode ◽  
Workpiece Surface ◽  
Aisi P20 ◽  
Edm Process ◽  
Aisi P20 Steel

The AISI P20 steel is applied by the tooling industry as material for injection molding tools. It is known that the EDM process parameters technology installed at the majority of CNC EDM machines do not cover some of the necessities of the tooling industry. So, the customers are required to develop their own process parameters. In order to provide useful technical information to the industry an experimental investigation on the EDM of the AISI P20 tool steel under finish machining has been carried out. The material removal rate Vw, volumetric relative wear v and workpiece surface texture Ra, which are representative of EDM performance aspects, were analyzed against the variation of some of the most important EDM electrical variables using copper tool electrodes under positive and negative polarity. The EDM machine generator was also programmed to actuate under isoenergetic mode and relaxation mode. The results are discussed and some appropriate parameters for EDM of AISI P20 are suggested.

Effects of the Profile of Workpiece Surface on Material Removal Rate Distribution in Polishing Process

2016 ◽  
Vol 851 ◽  
pp. 149-154
Author(s):  
Zhen Gang Wu ◽  
Dong Shan He ◽  
Ping Zhou ◽  
Dong Ming Guo
Keyword(s):  
Material Removal Rate ◽  
Material Removal ◽  
Removal Rate ◽  
Surface Profile ◽  
Prediction Method ◽  
Quantitative Prediction ◽  
Polishing Process ◽  
Workpiece Surface ◽  
Coefficient Distribution ◽  
Polishing Pad

Accurate prediction of the material removal rate (MRR) distribution is very important for the control of the polishing process. However, the widely used prediction method of MRR based on the Preston equation is still incapable of predicting the roll-off phenomenon in polishing process. One of the reasons is that many of the researchers’ neglected the effect of the surface profile of the workpiece on the MRR. In this paper, the evolutionary process of MRR distribution with the change of surface profile using two different polishing pad is studied, it is found that MRR varies gradually with the change of surface profile and tends to be uniform finally. Based on the analysis of contact pressure considering the actual surface profile of workpiece and modified Preston equation, the distribution of MRR is analyzed. It is found that the Preston coefficient distribution on workpiece surface is stable when the surface profile variation is small and shows obvious differences from the center to the edge of the workpiece. Through the comparison it is found that correlation between the regularities of Preston coefficient distribution and the type of polishing pad is significant. The research results in this paper will play an important guiding role in the quantitative prediction method research of polishing process.

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