3D elliptical vibration-assisted cutting (EVC) is a method for rapidly creating ultra-precision free-form surfaces with features at the micro-scale, which have a wide array of industrial applications. Displacement coupling and low stiffness limit the applications of current 3D EVC mechanisms in machining difficult to cut materials and precise micro-features. To overcome these limitations and improve overall performance, an innovative 3D EVC mechanism with a parallel layout with flexure hinges will be presented. The mechanism was specifically designed to be capable of generating decoupled output displacements in three directions and assuring high stiffness. An analytical model of the mechanism’s kinematics will be formulated to facilitate the prediction of the loci of the tooltip and design and realization of the prototype device. The vibration characteristics of the mechanism were verified through both finite element analysis and experimental modal analysis using swept sine testing. To validate the machining performance of the mechanism, two groups of micro-texturing turning and simulation experiments were performed. The performance tests and comparison results between the generated and simulated micro-textures indicate that the proposed 3D EVC mechanism is capable of generating different micro-feature shapes.
Textured surfaces have been widely applied in many fields due to their excellent functional performances. Although several micro-scale surface texturing techniques have been used to fabricate surface textures, most are either very expensive, have material limitations, or lack flexibility. In this study, a novel textured surface generation method using vibration-assisted ball-end milling with a non-resonant vibrator is proposed. Firstly, the configuration of the vibration-assisted ball-end milling system is introduced. Then, the trajectories of the cutting edges are modeled and analyzed. Furthermore, an analysis of a non-resonant vibrator is conducted. Finally, surface texture machining experiments are conducted, and the feasibility of the proposed vibration-assisted ball-end milling method for surface texture fabrication is verified.
Various micro-texturing techniques are used to generate the surface topography. However, conventional methods are inherently difficult to adapt for efficient production of micro-textures on cylindrical surface. In this paper, an ultrasonic elliptical vibration-assisted (UEVA) cutting technique based on discussed control parameters is proposed to fabricate the micro-texture on cylindrical surfaces. In the proposed UEVA micro-texturing method, a control model is developed based on shape and distribution parameters for the micro-texture. The locus of UEVA cutting is actively controlled with this EVA model to generate the micro-texture. The simulation model based on the proposed micro-texturing method is developed to predict the topography of the generated micro-texture. The cutting experiment to produce the micro-texture is conducted to verify the established control model. A comparison of the obtained results shows that the proposed UEVA micro-texturing method can be used to predict and generate the micro-texture on the cylindrical surfaces.
Carbon-fiber-reinforced plastic (CFRP) composites are inten-sively used in aircraft and aerospace industry thanks to their superior properties. Comparing to the conventional drilling (CD), vibrationassisted drilling (VAD) is a novel machining technique suitable for drilling CFRP. Still, multi-mode excita-tions with elliptical locus and low vibration performance limit the applications of current VAD schemes for CFRP. To over-come these limitations and improve the overall performance, an innovative longitudinal-torsional complexmode ultrasonic vibration-assisted actuator with single excitation and an ellip-tical locus is presented employing a piezoelectric transducer and a stepped horn with spiral grooves. The proposed actu-ator is specially designed to deliver elliptical vibration and assure high vibration performance of a tool tip. Analysis of the actuation mechanism for the longitudinal-torsional com-posite vibration mode is discussed, and its simplified model is developed. A detailed design process of this actuator is given. Its vibration characteristics are verified with both finite-elem-ent simulation and experimental modal analysis using a swept sine test. It is demonstrated the developed prototype achieved longitudinal-torsional elliptical vibration. To validate the machining performance of the actuator, two groups of drilling experiments were performed. These indicate that the proposed actuator is capable of drilling CFRP with improved machining performance.
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