Design and kinematic analysis of a novel decoupled 3D ultrasonic elliptical vibration assisted cutting mechanism

Zhang, Chen; Song, Yun hye

doi:10.1016/j.ultras.2019.03.012

Cited by 31 publications

(8 citation statements)

References 26 publications

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“…Moreover, the tool path exhibits a spatial elliptical curve as presented in Figure 20(a). 179,180 Zhao et al 181 designed a system for ultrasonic-assisted elliptical vibration grinding (UAEVG) for machining nano-ZrO 2 to improve its grindability. The integrated nonresonant design method was used to develop a cup-shaped tool transformer while optimizing the conical horn length.…”

Section: Advancements In Grindingmentioning

confidence: 99%

A comprehensive review on the grinding process: Advancements, applications and challenges

Kishore

Sinha

Singh

et al. 2022

Proceedings of the Institution of Mechanical Engineers, Part C:

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Grinding is a manufacturing process which significantly contributes in producing high precision and durable components required in numerous applications such as aerospace, defence and automobiles. This review article is focused to uncover history, witness the present and predict the future of the grinding process. While going through the literature, it has been observed that minimal work has been done in explaining the history, present status and future scopes of the grinding process. In this era of information and environmental awareness, sustainability aspects have become a primary concern of almost every research field. In the grinding process too, the research work includes ecological elements such as reducing the consumption of cutting fluids through minimum quantity lubrication, utilizing cryogenics, hybrid lubrication and cooling techniques that are still required to be explored critically. Further, some significant findings of the prevailing research in grinding include modification in grinding wheel surface, merging different grinding principles such as usages of the textured grinding wheel, ultrasonic grinding, 3D printing of grinding wheel and artificial intelligence in grinding are also presented. Another unascertained problem is the management of grinding swarf, which is being attended to by recycling it to fabricate composites which is expected to be another prominent domain of research. Further, the advancements taking place exhibit the potential of the grinding process, suggesting that its future is bright and ever-growing.

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Section: Advancements In Grindingmentioning

confidence: 99%

A comprehensive review on the grinding process: Advancements, applications and challenges

Kishore

Sinha

Singh

et al. 2022

Proceedings of the Institution of Mechanical Engineers, Part C:

View full text Add to dashboard Cite

show abstract

“…As the excitation frequency increases, not only does the stability of the entire system decrease, it is also difficult to guarantee the output power of the transducer with the existing manufacturing technology. When vibration is applied in three different directions at the same time, the resulting vibration displacement will cause a certain coupling phenomenon between each other, Studies [42] have shown that the orthogonal output structure can not only effectively reduce the impact caused by the different directions of vibration displacement, but also make it easier to combine and output vibration displacements in different directions. When the plane where the tool vibration path is located is coplanar with the plane where the chip discharge direction is located, a higher surface quality can be obtained.…”

Section: D-usvt Cutting Systemmentioning

confidence: 99%

Research on the formation mechanism of surface morphology in three-excitation ultrasonic spatial vibration-assisted turning

Duan

Zou

Wei

et al. 2022

Int J Adv Manuf Technol

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To improve the machining performance of different processing materials, a three-excitation ultrasonic spatial vibration-assisted turning system is proposed, which realizes the non-unity of the plane where the cutting trajectory of the tool is located. The influence and formation law of three-excitation ultrasonic spatial vibration-assisted turning on the surface roughness of the workpiece under different vibration parameters (amplitude) and machining parameters (cutting speed, cutting depth, and feed) were analyzed by response surface methodology. The results show that in terms of vibration parameters, the influence of ultrasonic vibration applied in the horizontal direction on surface roughness is significantly greater than that of ultrasonic vibration applied in the vertical direction, while the feed has the greatest influence on surface roughness, followed by cutting speed. The surface roughness of common turning, one-dimensional ultrasonic vibration-assisted turning, ultrasonic elliptical vibration-assisted turning, and three-excitation ultrasonic spatial vibration-assisted turning were theoretically analyzed and experimentally compared. The results show that compared with the other three turning methods, the three-excitation ultrasonic spatial vibration-assisted turning can obtain a lower surface roughness and have good machinability.

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“…Elliptical loci in 3D space can be, in principle, realized by applying three input displacements in three orthogonal directions [17]. However, depending on the mechanism's structure the three output displacements generating the elliptical locus will exhibit a certain degree of undesirable coupling.…”

Section: Conceptual Design Of the 3d Evc Mechanismmentioning

confidence: 99%

“…Compliant serial mechanisms are limited by their output motions, stiffness, heat balance, repeatability and resonant frequencies, to mention a few [15] while compliant parallel mechanisms offer the possibility for the design of compact monolithic structures to generate uniformly magnified output properties in all directions. Owing to their higher stiffness, the structures of EVC mechanisms [14][15][16][17], end manipulators [18][19][20][21] and positioning stages [22,23] have widely used compliant parallel mechanism configurations. They allow for the design of compact monolithic structures, through the combination of different types of flexure hinge-based mechanisms, i.e.…”

Section: Introductionmentioning

confidence: 99%

Design and experimental investigation of a parallel flexure hinge-based 3D elliptical vibration-assisted cutting mechanism

Zhang¹,

Song²,

Ehmann³

2020

J. Micromech. Microeng.

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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.

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Design and kinematic analysis of a novel decoupled 3D ultrasonic elliptical vibration assisted cutting mechanism

Cited by 31 publications

References 26 publications

A comprehensive review on the grinding process: Advancements, applications and challenges

A comprehensive review on the grinding process: Advancements, applications and challenges

Research on the formation mechanism of surface morphology in three-excitation ultrasonic spatial vibration-assisted turning

Design and experimental investigation of a parallel flexure hinge-based 3D elliptical vibration-assisted cutting mechanism

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