A Mechanistic Approach to the Prediction of Material Removal Rates in Rotary Ultrasonic Machining

Pei, Zhijian; Prabhakar, D.; Ferreira, Placid M.; Haselkorn, M.

doi:10.1115/1.2803288

Cited by 107 publications

(53 citation statements)

References 7 publications

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“…Desde entonces, los modelos se pueden agrupan en dos grupos: uno que se basa en un material frágil y el otro en un material dúctil (35,36). Entre ellos, hay modelos teóricos que tienen en cuenta el principio de rotura por indentación (34) mientras otros se basan en modelos mecanísticos (37). Adicionalmente, se pueden encontrar trabajos relacionados con desarrollos para recubrir las herramientas de diamante (17).…”

Section: Introductionunclassified

Posibilidades del mecanizado por ultrasonidos rotatorio para fomentar el uso de las cerámicas técnicas en el mercado Español actual

Arriola¹,

Gonzalo²,

Bengoetxea³

2012

Bol. Soc. Esp. Ceram. Vidr.

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Las propiedades mecánicas de las cerámicas técnicas son adecuadas para aplicaciones en diferentes sectores como la medicina (prótesis,...), automóvil (rodamientos,….), aeroespacial (loseta,…), óptica (láser,…), etc. donde se requieren características como la gran resistencia al desgaste, alta dureza y estabilidad termoquímica. Sin embargo, la fabricación de estos materiales es difícil y costosa, en algunos casos alcanzando el 90% del coste final, por lo que su aplicación está limitada. Este trabajo presenta el mecanizado por ultrasonidos rotatorio (RUM) como un proceso no convencional que permite la fabricación de piezas cerámicas con geometrías 3D complejas de manera ecológica y económica. Este método consiste en la eliminación de material utilizando una herramienta superabrasiva dotada de 3 movimientos: rotación, vibración axial ultrasónica (20 KHz) y avance contra la pieza fija. Este proceso combina el rectificado convencional y el mecanizado por ultrasonidos logrando mayores volúmenes de material evacuado manteniendo las fuerzas de corte bajas. De esta manera, se superan las limitaciones de los métodos convencionales utilizados actualmente, obteniendo procesos más precisos, flexibles y económicos. En definitiva, el RUM es un proceso prometedor para las operaciones de mecanizado de cerámicas estructurales. Sus características permitirán fomentar el uso de las cerámicas en un mayor número de aplicaciones industriales. Palabras clave: Aplicaciones estructurales, mecanizado, ultrasonidos, cerámica Possibilities of rotary ultrasonic machining in order to give a boost to technical ceramics in the actual Spanish marketThe advanced properties of engineering ceramics are suitable to meet the requirements of several engineering applications such as medical (prosthesis…), automotive (bearing...), aerospace (tiles,...), optics (lasers,…) and so on, where high hardness, high wear resistance and thermo chemical stability are needed. However, the processing of these materials is difficult and costly, in some cases up to 90% of the price, which leads ceramics to limited applications. Rotary Ultrasonic Machining (RUM) is presented as a non conventional environmental-friendly and cost effective process that enables to obtain complex 3D shape ceramic products. A rotating tool with metal-bonded diamond abrasives is ultrasonically vibrated (typically 20KHz) and fed toward to the fixed workpiece at a constant pressure or a constant feed rate This process combines conventional grinding and ultrasonic machining, offering the possibility of increased material removal rates while keeping the machining forces low. Thus, the limitations of actually used conventional processes are overcome introducing more accurate, flexible and cost effective process capabilities. On balance, RUM is a promising process for primary machining operations on structural ceramic components. Its features will lead to enhance the use of ceramics in more industrial applications by increasing product development/design capabilities, high added value products and...

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Section: Introductionunclassified

Posibilidades del mecanizado por ultrasonidos rotatorio para fomentar el uso de las cerámicas técnicas en el mercado Español actual

Arriola¹,

Gonzalo²,

Bengoetxea³

2012

Bol. Soc. Esp. Ceram. Vidr.

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“…A theoretical material removal model in drilling advanced ceramics was established based on brittle fracture mode [6]. This model discussed the relationship between cutting parameters and material removal rate (MRR) but not predicted the drilling force model [7].…”

Section: Introductionmentioning

confidence: 99%

“…In previous study and literature review [1][2][3][4][5][6][7][8][9][10][11][12][13][14][15][16][17], it is found that there was main focus on machining ceramics and its related composite materials. The research work on rotary ultrasonic drilling of CFRP materials is rare especially on CFRP-T700.…”

Section: Introductionmentioning

confidence: 99%

Development of a cutting force prediction model based on brittle fracture for carbon fiber reinforced polymers for rotary ultrasonic drilling

Yuan

Zhang

Amin

et al. 2015

Int J Adv Manuf Technol

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Carbon fiber reinforced polymers (CFRP) T700 have got increasing demand in the aerospace industry due to their high specific strength, specific stiffness, and other unique properties. Due to their inhomogeneous, anisotropic, and thermal properties, it is challenging to achieve desired accuracy and to avoid from delamination, chip-off, cracking, and burning especially in the drilling process. The cutting force is the critical parameter which is required to minimize in order to drill a hole with better accuracy and minimize defects. In this research, the brittle fracture approach was adopted and a cutting force model was developed for CFRP-T700 based on the rotary ultrasonic drilling (RUD) process. The experimental RUD was carried out on CFRP-T700 material and found that the feed rate and spindle speed are two main parameters that affect the cutting force in RUD. The cutting force data obtained from the model and experimental setup were then analyzed and found that there is small variation even below 10 % (max value of variation is 8.5 % and the average value is 0.49 %) between simulated and measured values. So, the developed cutting force model was validated and found robust. Also, it was found that with four times increase of feed rate, there is also an increase of material removal rate (MRR) four times with the decrease in the cutting force. Moreover, this model will be much helpful to keep cutting force within limits through the optimal set of parameters as feed rate and spindle speed without extensive experimentation of such costly materials.

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“…A better surface quality for the workpiece with less sub-surface damages (Qu et al, 2000). An increased material removal rate (Pei et al, 1995).…”

Section: Introductionmentioning

confidence: 99%

Parametric experimental study and design of experiment modelling of sapphire grinding

Wasmer

Pochon

Sage

et al. 2017

Journal of Cleaner Production

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a b s t r a c tThis study investigates and models the grinding process of single crystal sapphire. Five parameters: the wheel speed, the feed speed, the vertical feed, the ultrasonic assistance and the crystallographic direction were considered via a design of experiments (DoE) approach. The responses were multiple but can be divided in three groups: the process, the machine and the grinding quality. DoE results revealed that the parameters interact in a complex manner and depends on the responses. Therefore, to gain a better understanding of the grinding process of sapphire, the interactions between parameters have also to be taken into consideration. It was found that three main parameters have the largest influences on the tangential grinding forces: the wheel speed, the feed speed and the vertical feed. In contrast, the median defect area is mainly impacted by the quadratic effects of the wheel speed and vertical feed followed by various interactions. After an optimization procedure, the second optimum for the tangential forces was found to be very close to the best optimum for the median defect area. The optimum solution is: a wheel speed of 7 0 500 rpm, a feed speed of 60 mm/min, a vertical feed of 12.5 mm/pass, no ultrasonic assistance and grinding along the c-axis. This set of parameters was validated with additional and repeated tests on both Verneuil and Kyropouloas sapphire. Finally, it came out that the optimum solution has also a very good productivity.

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A Mechanistic Approach to the Prediction of Material Removal Rates in Rotary Ultrasonic Machining

Cited by 107 publications

References 7 publications

Posibilidades del mecanizado por ultrasonidos rotatorio para fomentar el uso de las cerámicas técnicas en el mercado Español actual

Posibilidades del mecanizado por ultrasonidos rotatorio para fomentar el uso de las cerámicas técnicas en el mercado Español actual

Development of a cutting force prediction model based on brittle fracture for carbon fiber reinforced polymers for rotary ultrasonic drilling

Parametric experimental study and design of experiment modelling of sapphire grinding

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