Developing a novel radial ultrasonic vibration-assisted grinding device and evaluating its performance in machining PTMCs

Zhao, Biao; Wu, Bangfu; Yue, Yansong; Ding, Wenfeng; Xu, Jianming; GUO, Guoqiang

doi:10.1016/j.cja.2023.01.008

Cited by 15 publications

(4 citation statements)

References 31 publications

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“…Compared with conventional grinding, the optimized two-dimensional workpiece UVAG reduced the cutting force and surface roughness by more than 10%. Zhao et al [96] created an innovative radial UVAG device, as illustrated in figure 9. The vibration converter designed with a special cross structure can achieve better vibration uniformity.…”

Section: Workpiece Ultrasonic Vibration-assisted Grindingmentioning

confidence: 99%

Nontraditional energy-assisted mechanical machining of difficult-to-cut materials and components in aerospace community: a comparative analysis

Zhao,

Ding

et al. 2024

Int. J. Extrem. Manuf.

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Difficult-to-cut materials such as titanium alloys, high-temperature alloys, metal/ceramic/polymer-matrix composites, hard and brittle materials, as well as geometrically complex components such as thin-walled structures, micro channels and complex surfaces, are widely used in aerospace community. Mechanical machining is the main material removal process and responsible for the vast majority of material removal for aerospace components. Nevertheless, it encounters many problems in terms of severe and rapid tool wear, low machining efficiency, and deteriorated surface integrity. Nontraditional energy-assisted mechanical machining is a hybrid process in which nontraditional energies, e.g., vibration, laser, electric, etc., are applied to improve the machinability of local material and decrease burden of mechanical machining. It provides a feasible and promising way for improving machinability and surface quality, reducing process forces, and prolonging tool life, etc. However, systematic reviews of this technology are lacking with respect to the current research status and development direction. This paper reviews recent progress in nontraditional energy-assisted mechanical machining of difficult-to-cut materials and components in aerospace community. It focuses on the processing principles, material responses under nontraditional energy, resultant forces and temperatures, material removal mechanisms and applications of these processes including vibration-, laser-, electric-, magnetic-, chemical-, cryogenic cooling-, and hybrid nontraditional energies-assisted mechanical machining. Eventually, a comprehensive summary of the principles, advantages and limitations for each hybrid process is provided, and future perspectives on forward design, device development and sustainability of nontraditional energy-assisted mechanical machining processes are discussed.

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Section: Workpiece Ultrasonic Vibration-assisted Grindingmentioning

confidence: 99%

Nontraditional energy-assisted mechanical machining of difficult-to-cut materials and components in aerospace community: a comparative analysis

Zhao,

Ding

et al. 2024

Int. J. Extrem. Manuf.

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“…In recent years, the introduction of ultrasonic vibration in grinding is a new method to improve the grinding quality of di cult-to-machine materials such as titanium alloys, nickel-based high-temperature alloys, ceramics and other materials in the aerospace industry [18][19][20][21][22][23][24][25][26]. Studies have shown that ultrasonic vibration-assisted grinding (UVAG) can introduce high-frequency micro-amplitude vibration, change the relative motion trajectory between the abrasive grain and the workpiece, so that the relative percentage of abrasive grain rubbing, ploughing, cutting effect changes, which can effectively reduce the grinding force and the grinding temperature, and enhance the integrity of the surface of the workpiece [26][27][28][29][30].…”

Section: Introductionmentioning

confidence: 99%

Wear mechanism of aggregated cBN grains during single-grain ultrasonic vibration-assisted grinding of γ-TiAl alloys

Song,

Zhao,

Ding

et al. 2024

Preprint

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In this study, the wear mechanism of single aggregated cubic boron nitride (AcBN) grain during ultrasonic vibration-assisted grinding is investigated. The single AcBN grinding experiment are conducted under conventional grinding and ultrasonic vibration-assisted grinding on gamma titanium-aluminum intermetallic compounds, and the grain wear mechanism is comprehensively revealed by observing the radial wear height, normal force, average volume pile-up ratio, and morphology evolution of the grains with different maximum undeformed chip thicknesses, grinding speeds, and ultrasonic amplitudes. The experimental results show that the introduction of ultrasonic vibration produces periodic vibration of the workpiece in the tangential direction, which can produce intermittent dissociative behavior and effectively reduce normal force and average volume pile-up ratio of single AcBN grains when grinding, but also makes the instantaneous maximum undeformed chip thickness increase and introduces the periodic impact force, which accelerates the radial wear height of the AcBN grains. In addition, the ultrasonic vibration can effectively reduce the material adhesion in the AcBN grains surface and cause it to continuously undergo micro-fracture has better self-sharpening ability. In addition, excessive ultrasonic amplitude will lead to AcBN grains to occur macro-fracture and the expansion of bond cracks lead to abrasive grains pulling out, losing partial grinding ability.

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“…In recent years, ultrasonic vibration-assisted grinding (UVAG) technology has been widely concerned, aiming at obtaining high surface integrity, especially for difficult-to-cut materials in aerospace industries [16]. Those researches show that the usage of ultrasonic composite technology contributes to the reduction of the grinding forces and temperature, the significantly improvement of grinding quality, and an enhancement in material removal rate during machining difficult-to-cut materials [17][18][19][20][21][22][23][24][25]. Ding et al [17] developed a radial ultrasonic vibration-assisted machining device and applied it to machining the particle-reinforcing titanium matrix composites.…”

Section: Introductionmentioning

confidence: 99%

“…Those researches show that the usage of ultrasonic composite technology contributes to the reduction of the grinding forces and temperature, the significantly improvement of grinding quality, and an enhancement in material removal rate during machining difficult-to-cut materials [17][18][19][20][21][22][23][24][25]. Ding et al [17] developed a radial ultrasonic vibration-assisted machining device and applied it to machining the particle-reinforcing titanium matrix composites. They found that the employment of radial ultrasonic vibrations can significantly reduce grinding temperature, and improve the processing efficiency.…”

Section: Introductionmentioning

confidence: 99%

Grindability of γ-TiAl intermetallic compounds during ultrasonic vibration-assisted high efficiency deep grinding process

Wang

Tang

Zhao

et al. 2023

Int J Adv Manuf Technol

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Gamma titanium-aluminum intermetallic compounds (γ-TiAl) have an important application significance in the field of aero-engines owing to their excellent mechanical properties (e.g., high-temperature resistance, high toughness, etc). Grinding as an important method was used to realize the high efficiency and precise machining for difficult-to-cut materials. However, the machining defects (e.g., adhesion, cracks, and even burns, etc) were confronted on machined surface of γ-TiAl materials under high grinding force and temperature loads. In this case, the new machining methods combined with the ultrasonic vibration and high-efficiency deep grinding technology was proposed to improve the machining quality and efficiency. Comparative trials of ultrasonic vibration-assisted high efficiency deep grinding (UVHEDG) and high efficiency deep grinding (HEDG) were carried out to study the grinding performance, in terms of the grinding force, grinding temperature, specific grinding energy, and machining surface quality. Results show that UVHEDG possess the lower grinding force and temperature by 38.69% and 39.05% compared with HEDG, respectively. In addition, the employment of ultrasonic vibrations contributes to maintain the abrasive sharpness, and thus the specific grinding energy is reduced by 23.95%. Ground surface roughness can be reduced by 19.53%, and the grinding surface quality is effectively improved due to the lubrication effect and track overlap effect under ultrasonic vibration.

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Developing a novel radial ultrasonic vibration-assisted grinding device and evaluating its performance in machining PTMCs

Cited by 15 publications

References 31 publications

Nontraditional energy-assisted mechanical machining of difficult-to-cut materials and components in aerospace community: a comparative analysis

Nontraditional energy-assisted mechanical machining of difficult-to-cut materials and components in aerospace community: a comparative analysis

Wear mechanism of aggregated cBN grains during single-grain ultrasonic vibration-assisted grinding of γ-TiAl alloys

Grindability of γ-TiAl intermetallic compounds during ultrasonic vibration-assisted high efficiency deep grinding process

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