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TakedownIf you consider content in White Rose Research Online to be in breach of UK law, please notify us by emailing eprints@whiterose.ac.uk including the URL of the record and the reason for the withdrawal request.Experimental investigations on effects of frequency in ultrasonically-assisted end-milling of AISI 316L: a feasibility study.A.
Abstract:The effects of frequency in ultrasonic vibration assisted milling (UVAM) with axial vibration of the cutter is investigated in this paper. A series of face-mill experiment in dry conditions were conducted on AISI 316L, an alloy of widespread use in industry. The finished surfaces roughness were studied along with basic considerations on tool wear for both conventional milling and an array of frequencies for UVAM in a wide range of cutting conditions. Surface residual stresses and cross-cut metallographic slides were used to investigate the hidden effects of UVAM.Experimental results showed competitive results for both surface roughness and residual stress in UVAM when compared with conventional milling especially in the low range of frequency with similar trend for tool wear.
Tooling used in machining of safety critical components are seldom used without highly frequent inspection. Worn or damaged tools produce undesirable surface finishes leading often to early failure of the part due to fatigue crack growth. In the development stages of polycrystalline boron nitride tools, an off-line run-to-failure method of tool wear inspection is undertaken which interrupts the cutting process intermittently to measure the tool wear using optical and scanning microscopy. The time consumption of this method leads to expensive tests and bottlenecks in the workshop. The overall aim in industry is to develop an on-line, automated system which is capable of informing the operator of the tool ′ s imminent failure. This paper focuses on treating this process as a preventative maintenance problem by studying whether acoustic emission can be used as an indirect measurement of tool wear at any given time. Acoustic emission measurements taken from the machining process of face turning are investigated here. Basic analysis in the frequency domain using principle component analysis reveals a number of interesting insights into the process. Relationships between the sharpness of the tool and the magnitude of the frequencies suggests promising link between acoustic emission and tool wear.
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