Elliptic vibration assisted cutting of metal matrix composite reinforced by silicon carbide: an investigation of machining mechanisms and surface integrity

Zhou, Jiakang; Lu, Mingming; Du, Yongsheng

doi:10.1016/j.jmrt.2021.08.096

Cited by 34 publications

(6 citation statements)

References 40 publications

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“…The author in [91] stated that the micro hardness and strength increased by 7.14% and 8.62%, as compared to the basic Al alloy while adding 10% SiC particles in the base matrix and that the inclusion of Mo with SiC showed a significant rise in the hardness value. During the examination of SiC/Al2O3 and aluminum powder using the Taguchi technique [92] found that the cutting speed and depth of cut have the greatest impact on surface roughness and cutting force [93] constructed a FE model and mounted an EVAC device on a CNC machining machine to turn SiC/Al composites to measure the cutting force and surface topography. The authors in [94] performed an experimental investigation utilizing Al6061 alloy with SiC reinforcement and concluded that hole diameter affects localized stress and chip breakability.…”

Section: Aluminium Reinforced With Silicon (Al/si)mentioning

confidence: 99%

Conventional Machining of Metal Matrix Composites towards Sustainable Manufacturing – Present Scenario and Future Prospects

Gutema,

Lemu

2024

Preprint

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This study provides an in-depth review of the available literature on metal composite material machining, focusing on traditional machining operations such as turning, milling, shaping, drilling, and grinding. The motivation for the study is that this composite type has emerged as a vital material in applications requiring functionality, resilience, cost-effective operation, low consumption of energy and lightweight. Despite its superior characteristics, the manufacturing complexity and poor machinability of metal matrix composites have been the primary barriers to its adoption. Nevertheless, there is a reduction of exceptional efficiency, increase in surface roughness, tool wear and so on in metal matrix composites throughout machining. As a result, this review gives a comprehensive investigation of metal matrix composite machining and effect on process parameters and procedures. Furthermore, this study distinguishes metal matrix composites towards sustainable manufacturing and the metals employed by the researchers, as well as the gaps discovered for future recommendations in metal-based composites.

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Section: Aluminium Reinforced With Silicon (Al/si)mentioning

confidence: 99%

Conventional Machining of Metal Matrix Composites towards Sustainable Manufacturing – Present Scenario and Future Prospects

Gutema,

Lemu

2024

Preprint

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“…At the same time, the material removal rate and lapping force of a single abrasive increases, resulting in more surface damage to SiCp/Al and an increase in SiC particle shedding and particle fracture on the machined surface, which affects the surface quality after machining. The difference between experimental and simulation results of feed speed v f may be due to different parameter Settings, and the abrasive motion path of the NVL method is dependent on the spindle speed [ 24 , 35 ].…”

Section: Test Of Vibration-assisted Lapping Device and Lapping Experi...mentioning

confidence: 99%

“…Researchers have tried to apply the non-resonant vibration device to vibration-assisted cutting (VC) [ 23 , 24 ], vibration-assisted milling (VM) [ 25 ], and vibration-assisted polishing (VP) [ 26 , 27 ] and achieved good results. Zhou et al designed an elliptical VC device and studied the removal mechanism, cutting force, surface roughness, and microstructure in elliptical VC.…”

Section: Introductionmentioning

confidence: 99%

“…Zhou et al designed an elliptical VC device and studied the removal mechanism, cutting force, surface roughness, and microstructure in elliptical VC. The orthogonal cutting experiments showed that the periodically changing cutting trajectory reduced the average cutting force and improved the surface quality [ 24 ]. Zheng et al showed that applying vibration on a micro-milling cutter can help improve tool life, and this method can improve surface roughness.…”

Section: Introductionmentioning

confidence: 99%

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Simulation and Experimental Study of Non-Resonant Vibration-Assisted Lapping of SiCp/Al

Zhao,

Gu,

et al. 2024

Micromachines

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SiCp/Al is a difficult-to-machine material that makes it easy to produce surface defects during machining, and researchers focus on reducing the surface defects. Vibration-assisted machining technology is considered an effective method to reduce surface defects by changing the trajectory and contact mode of the abrasive. Aiming at the problem of SiCp/Al processing technology, a vibration-assisted lapping device (VLD) is designed, and elliptical motion is synthesized by a set of parallel symmetrical displacement output mechanisms. The working parameters of the device were tested by simulation and experiment, and the lapping performance was verified. Then, the effects of removal characteristics and process parameters on surface roughness and lapping force were analyzed by simulation and experiment. Simulation and experimental results show that frequency and amplitude that are too low or too high are not conducive to the advantages of NVL. The best surface quality was 54 nm, obtained at A = 8 μm and f = 850 Hz.

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“…Thus, UEVC can effectively reduce cutting forces [3][4][5][6] and cutting heat [7,8], thereby improving the surface quality of workpieces [9][10][11][12][13] while significantly extending the lifespan of the tool [12,14,15]. It is particularly suitable for precision and ultra-precision machining of hardened steel [1,16], ceramics [17,18], silicon carbide [19,20], tungsten carbide [21,22], and other hard and brittle materials.…”

Section: Introductionmentioning

confidence: 99%

Developmental and Experimental Study on a Double-Excitation Ultrasonic Elliptical Vibration-Assisted Cutting Device

Hu,

Xin,

Zhang

et al. 2024

Machines

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Ultrasonic elliptical vibration-assisted cutting (UEVC) has been successfully applied in the precision and ultra-precision machining of hard and brittle materials due to its advantages of a low cutting force and minimal tool wear. This study developed a novel double-excitation ultrasonic elliptic vibration-assisted cutting (D-UEVC) device by coupling ultrasonic vibrations in orthogonal dual paths. A two-degree-of-freedom vibration system of the D-UEVC was modeled, form which the elliptical trajectory of the end under different phase angle φ values was derived. The initial dimensions of the D-UEVC device were obtained through theoretical calculations. Subsequently, with the aid of finite element analysis methods, structural dynamic analysis of the device was conducted to obtain the elliptical vibration trajectory under different phase differences of the excitation source. In order to verify the cutting trajectory and cutting performance of the D-UEVC device, a prototype of the device was developed, and a series of vibration performance tests as well as the Inconel 718 cutting experiment were conducted. The experimental results illustrated that the D-UEVC device can achieve the elliptical vibration trajectory at the tool tip with a resonant frequency of 36.5 KHz. The adjustable elliptical vibration trajectories covered a range of ±4 μm in the axial and radial directions. Compared with the surface roughness Ra = 0.36 μm under the conventional cutting, the surface roughness of Inconel 718 under D-UEVC was Ra = 0.215 μm. Thus, the surface quality can be significant improved by utilizing the D-UEVC device.

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Elliptic vibration assisted cutting of metal matrix composite reinforced by silicon carbide: an investigation of machining mechanisms and surface integrity

Cited by 34 publications

References 40 publications

Conventional Machining of Metal Matrix Composites towards Sustainable Manufacturing – Present Scenario and Future Prospects

Conventional Machining of Metal Matrix Composites towards Sustainable Manufacturing – Present Scenario and Future Prospects

Simulation and Experimental Study of Non-Resonant Vibration-Assisted Lapping of SiCp/Al

Developmental and Experimental Study on a Double-Excitation Ultrasonic Elliptical Vibration-Assisted Cutting Device

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