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.

Two Dimensional Ultrasonic Vibration Assisted Chemo-Mechanical Grinding of Si Wafer

2010 ◽  
Vol 126-128 ◽  
pp. 282-288
Author(s):  
Zhen Zhong Wang ◽  
Yong Bo Wu ◽  
Li Bo Zhou ◽  
Yin Biao Guo ◽  
Chen Xu Wu
Keyword(s):  
Ultrasonic Vibration ◽  
Material Removal ◽  
Removal Rate ◽  
Surface Damage ◽  
Vibration Modes ◽  
Two Dimensional ◽  
Mechanical Grinding ◽  
Grinding Method ◽  
Fixed Abrasive ◽  
Si Wafer

As a new fixed-abrasive machining method, chemo-mechanical grinding (CMG) is developed from chemical mechanical polishing (CMP), with the obvious advantage of geometric accuracy determinacy and no slurry. To improve material removal rate and enhance the popularity of CMG, this paper introduces a combined grinding method, i.e., two dimensional ultrasonic vibration assisted CMG (2D-UACMG). Si wafer is taken as the workpiece and the influence of ultrasonic vibration modes and process parameters on the surface roughness and the material removal is examined. The results show 2D-UACMG can obtain better surface quality with little surface damage at nanometer level compared with the conventional CMG without the ultrasonic vibration.

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.

Ultrasonic Vibration Assisted Mechanical Chemical Polishing (MCP) of Silicon Carbide

2012 ◽  
Vol 565 ◽  
pp. 255-260
Author(s):  
Yunn Shiuan Liao ◽  
Y.P. Yu ◽  
C.W. Huang
Keyword(s):  
Silicon Carbide ◽  
Ultrasonic Vibration ◽  
Material Removal Rate ◽  
Ferric Oxide ◽  
Material Removal ◽  
Removal Rate ◽  
Ultrasonic Transducer ◽  
Chemical Polishing ◽  
Working Pressure ◽  
Polishing Efficiency

The mechanical chemical polishing (MCP) process which uses soft abrasives to polish hard workpiece have been employed recently to polish silicon carbide (SiC) ceramic for various applications. An ultrasonic vibration assisted apparatus is designed to investigate the effects of ultrasonic vibration on the efficiency of MCP of SiC by ferric oxide (Fe2O3) abrasives. Experimental results show that the ultrasonic vibration can effectively improve polishing efficiency; the material removal rate is increased by about 60~70%. But it does not lead to a better final surface finish. The effect is more obvious under a higher working pressure condition. It is also found that the output power of ultrasonic transducer is positively correlated with material removal rate. The rise of polishing efficiency is attributed to the increase of local asperities temperatures which promote chemical reaction of silicon carbide with oxygen to form passivation layers. The layers are removed by ferric oxide abrasives afterward.

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 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.

Chip-Ejection Mechanism and Experimental Study of Water Dispersant Dielectric Fluid on Small-Hole EDM

2010 ◽  
Vol 97-101 ◽  
pp. 4111-4115 ◽  
Author(s):  
Ming Rang Cao ◽  
Sheng Qiang Yang ◽  
Wen Hui Li ◽  
Shi Chun Yang
Keyword(s):  
Material Removal Rate ◽  
Material Removal ◽  
Removal Rate ◽  
Tap Water ◽  
Dielectric Liquid ◽  
Small Hole ◽  
Dielectric Fluid ◽  
Tool Electrode ◽  
Machining Quality ◽  
Hole Machining

The small hole EDM is one main method of micro holes machining and applied very widely. But it’s machining efficiency is low and machining stability is bad, which is more obvious because of chip-ejection difficulty when the ratio of length to diameter is rather large. Secondary discharge caused by chip-ejection difficulty not only makes the material removal rate reduce, but also causes geometric tolerance and affects product performance. Based on dispersion mechanism study of the water dispersant, the influence of the water dispersant is analyzed to chip-ejection, material removal rate and machining quality of the high-speed small-hole EDM. By contrasting the machining effect on using tap water with disperser dielectric liquid during electric spark small hole machining, adding the certain proportion disperser in water-based dielectric liquid may increase the material removal rate, decrease the tool wear rate, improve the effective impulse numbers, obviously reduce the second discharge number, and the taper of tool electrode and hole becomes small, so the hole machining quality enhances.

Comparative Study and Mathematical Modeling of Machining Parameters in Ultrasonic-Assisted EDM of AISI H13 Tool Steel by the Application of Workpiece Vibration

2010 ◽  
Vol 154-155 ◽  
pp. 1604-1613
Author(s):  
Mohammad Reza Shabgard ◽  
Babak Sadizadeh ◽  
Keivan Amini ◽  
Hamid Pourziaie
Keyword(s):  
Comparative Study ◽  
Ultrasonic Vibration ◽  
Material Removal Rate ◽  
Material Removal ◽  
Removal Rate ◽  
Correct Selection ◽  
Machining Parameters ◽  
Machining Performance ◽  
Ultrasonic Assisted ◽  
Aisi H13

The correct selection of the machining parameters is one of the most significant issues to take into consideration in Ultrasonic-assisted Electrical Discharge Machining (US-EDM) and EDM processes. In the present work, a study has been made to develop and extract statistical models to show the relationship between important machining performance data (material removal rate (MRR), tool wear ratio (TWR) and surface roughness Ra) and the input machining parameters (pulse current, and pulse-on time) in the EDM and US-EDM of AISI H13. The models obtained were used to analyze the effects of input parameters on machining performance. In addition, a comparative study was carried out to investigate the effect of ultrasonic vibration of the workpiece on machining performance. The results show that Ultrasonic vibration of the workpiece can significantly reduce the inactive pulses and improves the stability of process. Also US-EDM is effective in attaining a high material removal rate (MRR) in finishing regime in comparison with conventional EDM. The results of Analysis of Variance (ANOVA) indicate that the proposed mathematical models can adequately explain the performance within the limits of the factors being studied.

Experimental Study on the Subsurface Damage in the Ultrasonic Vibration Grinding of Nano-ZrO2 Ceramics

2010 ◽  
Vol 42 ◽  
pp. 143-146 ◽  
Author(s):  
Ming Li Zhao ◽  
Bo Zhao ◽  
Yu Qing Wang ◽  
Ling Zhi Kong
Keyword(s):  
Ultrasonic Vibration ◽  
Vibration Mode ◽  
Longitudinal Vibration ◽  
Subsurface Damage ◽  
Bending Vibration ◽  
Effect Factor ◽  
Damage Layer ◽  
Grinding Method ◽  
Ultrasonic Grinding ◽  
Longitudinal Vibration Mode

Because of the hard-brittle character of ceramics, the ultrasonic vibration grinding method was used in the experiment. And the effects of ultrasonic vibration on the subsurface damage were analyzed in this paper. The experiment indicates that the frequency of 35 KHz will be more suitable for ultrasonic grinding ceramics, and under this frequency the damage layer thickness will be controlled in 11μm. The effect of vibration amplitude on the subsurface damage was also analyzed in this paper. The experiment results show that smaller amplitude will impair the efficiency of ultrasonic vibration grinding. The ultrasonic vibration mode was also an effect factor to the subsurface damage. Only the longitudinal vibration mode can improve the subsurface quality, while the bending vibration and torsion vibration will lead to the contrary results.

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