Development of Fixing System for 2-Axis Micro Deep Drilling Assisted by Low Frequency Vibration

2014 ◽  
Vol 625 ◽  
pp. 149-154 ◽  
Author(s):  
Ivan Burdukovskyi ◽  
Jun'ichi Kaneko ◽  
Kenichiro Horio
Keyword(s):  
Amplitude Ratio ◽  
Low Frequency ◽  
Two Dimensions ◽  
Drilling Process ◽  
Vibration Source ◽  
Deep Drilling ◽  
Machining Time ◽  
Hard Materials ◽  
Low Frequency Vibration ◽  
Vertical Displacements

Micro deep drilling of hard materials is required to involve step feed in process that grows up machining time. To increase the step feed, a method with low frequency vibration (frequency ~190 Hz, amplitude ~10 μm) by oscillating of workpiece has been proposed. Previous study is focused on method of 1-axis drilling process assisted by low frequency vibration. Introducing the method with low frequency vibration to 2-axis drilling process on a curved surface is required to oscillate the workpiece in two dimensions. Purpose of our study is to design fixing system with the 2-dimansional low frequency vibration. Vibration source is needed to change for providing the 2-dimansional vibration. Fixing system for 2-dimensional vibration (FS2DV) consists of two vibration sources in horizontal and vertical directions with spring systems along it action. The 2-dimensional vibration is controlled by amplitude ratio of the vibrations from each source. As a result, we have succeeded low frequency vibration of the workpiece with assigned direction. The resulting vibration is verified (measuring of instantaneous horizontal and vertical displacements).

Configuration Method of Fixing System with 2-Dimensionally Low-Frequency Vibration for Drilling to Decrease Influence from Unintended Displacement of Workpiece

2015 ◽  
Vol 9 (2) ◽  
pp. 161-169
Author(s):  
Ivan Burdukovskyi ◽  
◽  
Jun’ichi Kaneko ◽  
Kenichiro Horio
Keyword(s):  
Vibration Frequency ◽  
Thrust Force ◽  
Function Analysis ◽  
Low Frequency ◽  
Drilling Process ◽  
Deep Drilling ◽  
Machining Time ◽  
Hard Materials ◽  
Error Frequency ◽  
Low Frequency Vibration

Micro deep drilling of hard materials requires introducing of step feed in process that increases machining time. To decrease the machining time by increasing the step feed, we apply low-frequency vibration (∼10 μm, 150 – 250 Hz) to the drilling process by oscillating the workpiece. To cope with the low-frequency vibration-assisted drilling of a curved surface, we have developed a fixing system for 2-dimensional vibration. The Fixing System for 2-Dimensional Vibration (FS2DV) consists of horizontal, and vertical actuators plus spring systems with variable rigidities along the directions of the actuators. A thrust force of 6 – 10 N from the drilling process may induce an unintended displacement of the workpiece. If the rigidities of the horizontal and the vertical spring systems are not balanced, unintended displacement may create diameter error during the drilling process. In this study, a method is proposed for configuring of the FS2DV with balanced spring systems to minimize the effects of the unintended displacement on diameter error. Frequency response function analysis of the vertical and horizontal spring systems is done for successful use of the FS2DV during the low-frequency vibration-assisted 2-axis drilling. Based on this analysis, setting requirements for the FS2DV are proposed for a particular vibration frequency. The behavior of the resultant vibration is evaluated while force is loaded along the intended angle of the drilling process. As a result, the effects of unintended displacement at the FS2DVare decreased for use within the vibration frequency range of 150 – 250 Hz with the vibration amplitude of 10 μm. The system can be used properly with a thrust force of up to 10 N and any angle from 0 to 90° by selecting appropriate rigidities for the spring systems.

Numerical Model for Prediction of Cutting Forces in a Vibratory Drilling Process

2014 ◽  
Vol 1016 ◽  
pp. 215-220 ◽  
Author(s):  
Nawel Glaa ◽  
Kamel Mehdi ◽  
Moez Ben Jaber
Keyword(s):  
Cutting Forces ◽  
Three Dimensional ◽  
Low Frequency ◽  
Cutting Parameters ◽  
Forced Vibrations ◽  
Drilling Process ◽  
Drilling Operation ◽  
Low Frequency Vibration ◽  
Cutting Force Components ◽  
Force Components

The drilling operation is considered by manufacturers as complex and difficult process (rapid wear of the cutting edge as well as problems of chip evacuation). Faced with these failures, manufacturers have shifted in recent years towards the drilling process assisted by forced vibrations. This method consist to add an axial oscillation with a low frequency to the classical feed movement of the drill so as to ensure good fragmentation and better chip evacuation. This paper presents a model for prediction of cutting forces during a drilling operation assisted by forced low-frequency vibration. The model allows understanding the interaction between the tool and the workpiece and identifying numerically the three-dimensional evolution of the cutting force components generated by the vibratory drilling operation. The effects of cutting parameters, tool parameters and those of forced vibrations on the cutting forces distributions will be discussed.

scholarly journals The effect of MQL on tool wear progression in low-frequency vibration-assisted  drilling of CFRP/Ti6Al4V stack material

2021 ◽  
Author(s):  
Ramy Hussein ◽  
Ahmad Sadek ◽  
Mohamed Elbestawi ◽  
Helmi Attia
Keyword(s):  
Tool Wear ◽  
Vibration Amplitude ◽  
Cutting Temperature ◽  
Cutting Speed ◽  
Chip Thickness ◽  
Low Frequency ◽  
Drilling Process ◽  
Machining Parameters ◽  
Geometrical Accuracy ◽  
Low Frequency Vibration

Abstract In this paper, the tool wear mechanism in low-frequency vibration-assisted drilling (LF-VAD) of carbon fiber reinforced polymer (CFRP)/Ti6Al4V stacks has been proposed using variably machining parameters. Based on the kinematics analysis, the effect of vibration amplitude on the chip formation, uncut chip thickness, chip radian, and axial velocity was presented. Subsequently, the effect of LF-VAD on the cutting temperature, tool wear, delamination, and geometrical accuracy was presented for different vibration amplitude. The LF-VAD with the utilization of minimum quantity lubricant (MQL) resulted in a successful drilling process of 50 holes, with a 63 % reduction of the cutting temperature. For the rake face, LF-VAD reduced the adhered height of Ti6Al4V by 80 % at low cutting speed and reduced the crater depth by 33 % at the high cutting speed. On the other hand, LF-VAD reduced the flank wear land by 53 %. Furthermore, LF-VAD showed a significant enhancement on the CFRP delamination, geometrical accuracy, and burr formation.

scholarly journals Performance Enhancement of a Multiresonant Piezoelectric Energy Harvester for Low Frequency Vibrations

Energies ◽  
2019 ◽  
Vol 12 (14) ◽  
pp. 2770 ◽  
Author(s):  
Iman Izadgoshasb ◽  
Yee Lim ◽  
Ricardo Vasquez Padilla ◽  
Mohammadreza Sedighi ◽  
Jeremy Novak
Keyword(s):  
Cantilever Beam ◽  
Performance Enhancement ◽  
Low Frequency ◽  
Design Parameters ◽  
Vibration Source ◽  
Element Analysis ◽  
Energy Harvesters ◽  
Piezoelectric Energy ◽  
Low Frequency Vibration ◽  
External Power Source

Harvesting electricity from low frequency vibration sources such as human motions using piezoelectric energy harvesters (PEH) is attracting the attention of many researchers in recent years. The energy harvested can potentially power portable electronic devices as well as some medical devices without the need of an external power source. For this purpose, the piezoelectric patch is often mechanically attached to a cantilever beam, such that the resonance frequency is predominantly governed by the cantilever beam. To increase the power generated from vibration sources with varying frequency, a multiresonant PEH (MRPEH) is often used. In this study, an attempt is made to enhance the performance of MRPEH with the use of a cantilever beam of optimised shape, i.e., a cantilever beam with two triangular branches. The performance is further enhanced through optimising the design of the proposed MRPEH to suit the frequency range of the targeted vibration source. A series of parametric studies were first carried out using finite-element analysis to provide in-depth understanding of the effect of each design parameters on the power output at a low frequency vibration. Selected outcomes were then experimentally verified. An optimised design was finally proposed. The results demonstrate that, with the use of a properly designed MRPEH, broadband energy harvesting is achievable and the efficiency of the PEH system can be significantly increased.

scholarly journals Research and Design the Thrust Fluctuation of Slotted-Tubular Permanent Magnet Linear Motor: an application on low frequency plastic forming equipment

2021 ◽  
Author(s):  
Jingzhou Gao ◽  
Jingxiang Li ◽  
Shengdun Zhao ◽  
Wei Du ◽  
Fei Jiang ◽  
...  
Keyword(s):  
Permanent Magnet ◽  
Low Frequency ◽  
Vibration Source ◽  
Core Component ◽  
Stator Core ◽  
Low Frequency Vibration ◽  
Plastic Forming ◽  
Permanent Magnet Linear Motor ◽  
Research And Design ◽  
Thrust Fluctuation

Abstract In this paper, a novel type of low frequency vibration plastic forming equipment is proposed, in which the slotted tubular permanent magnet synchronous liner motor (slotted – TPMLM) is the core component and plays the roles of power source and vibration source. So, this paper focuses on the research about the design of the slotted - TPMLM. The suppression and optimization of motor thrust fluctuation has always been a hot research issue. But that is not the purpose of this article. Here, the effect of the length of stator core on end force and the influence of the number of poles and slots on the cogging force are discussed in detail. The purpose is to design the thrust fluctuation of slotted – TPMLM reasonably so that the thrust fluctuation can be used in the low frequency plastic forming. The slotted – TPMLM is designed, manufactured, and tested. The experimental results show that the motor can output thrust with periodic fluctuation (low frequency, about 4.8 Hz), and the thrust fluctuation accounts for about 16.5% of the average thrust, which meets the metal low frequency vibration plastic forming requirements. Consequently, the low frequency vibration plastic forming equipment can be realized, which contributes to the field of the plastic forming.

scholarly journals The Effect of MQL on Tool Wear Progression in Low-Frequency Vibration-Assisted Drilling of CFRP/Ti6Al4V Stack Material

2021 ◽  
Vol 5 (2) ◽  
pp. 50
Author(s):  
Ramy Hussein ◽  
Ahmad Sadek ◽  
Mohamed A. Elbestawi ◽  
M. Helmi Attia
Keyword(s):  
Tool Wear ◽  
Cutting Temperature ◽  
Cutting Speed ◽  
Chip Thickness ◽  
Low Frequency ◽  
Burr Formation ◽  
Drilling Process ◽  
Machining Parameters ◽  
Geometrical Accuracy ◽  
Low Frequency Vibration

In this paper, the tool wear mechanisms for low-frequency vibration-assisted drilling (LF-VAD) of carbon fiber-reinforced polymer (CFRP)/Ti6Al4V stacks are investigated at various machining parameters. Based on the kinematics analysis, the effect of vibration amplitude on the chip formation, uncut chip thickness, chip radian, and axial velocity are examined. Subsequently, the effect of LF-VAD on the cutting temperature, tool wear, delamination, and geometrical accuracy was evaluated for different vibration amplitudes. The LF-VAD with the utilization of minimum quantity lubricant (MQL) resulted in a successful drilling process of 50 holes, with a 63% reduction in the cutting temperature. For the rake face, LF-VAD reduced the adhered height of Ti6Al4V by 80% at the low cutting speed and reduced the crater depth by 33% at the high cutting speed. On the other hand, LF-VAD reduced the flank wear land by 53%. Furthermore, LF-VAD showed a significant enhancement on the CFRP delamination, geometrical accuracy, and burr formation.

Nonlinear Dynamics in Drilling and Boring Operations Assisted by Low Frequency Vibration

2007 ◽  
Author(s):  
George F. Moraru
Keyword(s):  
Nonlinear Dynamics ◽  
Harmonic Balance ◽  
Low Frequency ◽  
Harmonic Balance Method ◽  
Nonlinear Behavior ◽  
Drilling Process ◽  
Process Damping ◽  
Regenerative Effect ◽  
Low Frequency Vibration ◽  
Machining System

The nonlinear dynamics of the drilling process assisted by self-excited axial vibrations is analyzed. Models are developed and discussed, including regenerative effect and various phenomena contributing to the process damping in drilling and boring operations. Stability and bifurcation analysis, using several assumptions on the damping in the cutting process, are carried out using linear analysis tools or simulations. A simple predictive model based on a harmonic balance method is presented. Behavior charts are constructed using simulations. Hypothesis on the nature of the process damping and nonlinear behavior of the machining system are proved by experiments. A possible application to the gundrilling boring process in aircraft drilling and assembly process is presented.

scholarly journals Design of a contactless powered and piezoelectric-actuated tool for non-resonant low-frequency vibration-assisted machining of brittle-hard materials

2021 ◽  
Author(s):  
Jens Brier ◽  
Friedrich Bleicher
Keyword(s):  
Low Frequency ◽  
Maximum Amplitude ◽  
System Configuration ◽  
Hard Materials ◽  
Low Frequency Vibration ◽  
Ultrasonic Assisted ◽  
Tool Shape ◽  
Process Heating ◽  
Working Frequency ◽  
Actuator Design

AbstractUltrasonic-assisted grinding (UAG) is the state-of-the-art process for machining of brittle-hard materials. In comparison to conventional processes, the main advantages lie in the reduction of tool wear and process forces. Such a vibration system is based on a resonant actuator and a power supply unit generating the alternating current. Both units are interconnected by a contactless energy transfer (CET) system. This system configuration shows one optimal working point at the resonant frequency with maximum amplitude, which is significantly depending on the tool shape. In this work, a piezo-activated tool system is designed to realize non-resonant low-frequency vibrations. Major emphasis is put on the thermal behavior of the piezo drive, particularly on the in-process heating depending on the working frequency. In addition, focus lays on the theoretical and numerical design of the radial operating transducer CET system for a previously set actuator design. As a result, this system configuration offers a fully variable adjustment of the amplitude from under 1 to over 50 μm at frequency range. Outside this range, higher amplitudes can be achieved for short periods to the detriment of the fatigue strength according to FKM.

scholarly journals Development of a Low-Frequency Vibration-Assisted Drilling Device for Difficult-to-Cut Materials

2021 ◽  
Author(s):  
Feng Jiao ◽  
Yuanxiao Li ◽  
Dong Wang ◽  
Jinglin Tong ◽  
Ying Niu
Keyword(s):  
Titanium Alloy ◽  
Elastic Recovery ◽  
Structural Parameters ◽  
Low Frequency ◽  
Load Condition ◽  
Flexure Hinge ◽  
Drilling Process ◽  
Secondary Damage ◽  
Low Frequency Vibration ◽  
Drilling Temperature

Abstract In the drilling process of difficult-to-cut materials, conventional drilling has resulted in various problems such as high drilling temperature and poor machining quality. Low-frequency vibration-assisted drilling has great potential in overcoming these problems since broken chips are generated. In order to promote the application of low-frequency vibration-assisted drilling device in machining difficult-to-cut materials. In this paper, a low-frequency vibration-assisted drilling device is developed by using a novel ring flexure hinge as the elastic recovery mechanism. First, based on the theory of elastic mechanics and mechanical vibration, the stiffness of the ring flexure hinge is designed theoretically, and the influence of its structural parameters on its deflection is analyzed. And then the correctness of the theoretical design is further verified by static and dynamic simulation and stiffness test. Finally, the vibration performance of the device is tested under no-load condition, and the actual drilling test is conducted to verify the drilling performance. The results show that the device could realize the axial low-frequency vibration with constant frequency-to-rotation ratio and amplitude stepless adjustment and present good working stability under no-load and load conditions. In the actual drilling test of titanium alloy and carbon fiber reinforced plastic (CFRP)/ titanium alloy laminated structure, the device under appropriate processing parameters breaks the titanium alloy chip into small pieces and reduces the drilling temperature by 44% and inhibits the secondary damage of CFRP. It is demonstrated that the device could meet the actual processing requirements. And it also provides guidance for the design of low-frequency vibration-assisted drilling device.

Parameters Optimization of Axial Vibration Drilling Based on the Exit Burr

2013 ◽  
Vol 470 ◽  
pp. 429-432
Author(s):  
Hui Lin Wang ◽  
Ping Kuan Zhang ◽  
Qiao Ying Li
Keyword(s):  
Low Frequency ◽  
Optimization Method ◽  
Parameters Optimization ◽  
Drilling Process ◽  
Axial Vibration ◽  
Low Frequency Vibration ◽  
Solid Foundation ◽  
Vibration Drilling ◽  
Exit Burr

Based on analyzing the mechanism of forming exit burr in drilling, the paper researches the process of forming exit burr in low frequency vibration drilling. The calculate formula of exit burr is achieved after calculate the force of axial and other forces in low frequency vibration drilling, which is also proved the reliability by the experiment. The parameters optimization method is available in order to reduce or mitigate the low frequency axial vibration drilling. It is lay a solid foundation for selecting the reasonable parameters of vibrating drilling process in the theory.

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