Experimental and analytical study of ultrasonic elliptical vibration cutting on AISI 1045 for sustainable machining of round-shaped microgroove pattern

Kurniawan, Rendi; Kumaran, S. Thirumalai; Ali, Saood; Nurcahyaningsih, Dwi Ayu; Kiswanto, Gandjar; Ko, Tae Jo

doi:10.1007/s00170-018-2359-1

Cited by 41 publications

(19 citation statements)

References 63 publications

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“…However, the bottom surface roughness of the machined micro-groove produced by the CC process was 0.247 μm, which was more than two times than the roughness in the UEVC process with TSR = 1/24 or TSR = 1/48. Therefore, the application of the UEVC technology led to an obvious improvement of the machined micro-groove in surface integrity, which was consistent with the experimental result from the research literature [33,34,35,36,37].…”

Section: Resultssupporting

confidence: 89%

“…Their results demonstrated that the machining quality of micro-grooves improved and the cutting forces were reduced in the UEVC process, especially for stainless steel. Similarly, the experimental results obtained by Kurniawan et al [37] indicated that the UEVC process has shown many advantages in the machining of micro-grooves on steel alloy compared to the CC process.…”

Section: Introductionmentioning

confidence: 72%

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Experimental Investigation on Micro-Groove Manufacturing of Ti-6Al-4V Alloy by Using Ultrasonic Elliptical Vibration Assisted Cutting

et al. 2019

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The micro-groove structure on the planar surface has been widely used in the tribology field for improving the lubrication performance, thereby reducing the friction coefficient and wear. However, in the conventional cutting (CC) process, the high-quality, high-precision machining of the micro-groove on titanium alloy has always been a challenge, because considerable problems including poor surface integrity and a high level of the material swelling and springback remain unresolved. In this study, the ultrasonic elliptical vibration assisted cutting (UEVC) technology was employed, which aimed to minimize the level of the material swelling and springback and improve the machining quality. A series of comparative investigations on the surface defect, surface roughness, and material swelling and springback under the CC and UEVC processes were performed. The experimental results certified that the material swelling and springback significantly reduced and the surface integrity obviously improved in the UEVC process in comparison to that in the CC process. Furthermore, for all the predetermined depths of the cut, when the TSR (the ratio of the nominal cutting speed to the peak horizontal vibration speed) was equal to one of twenty four or one of forty eight, the accuracy of the machined micro-groove depth, width and the profile radius reached satisfactorily to 98%, and the roughness values were approximately 0.1 μm. The experimental results demonstrate that the UEVC technology is a feasible method for the high-quality and high-precision processing of the micro-groove on Ti-6Al-4V alloy.

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Section: Resultssupporting

confidence: 89%

Section: Introductionmentioning

confidence: 72%

Experimental Investigation on Micro-Groove Manufacturing of Ti-6Al-4V Alloy by Using Ultrasonic Elliptical Vibration Assisted Cutting

et al. 2019

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“…Recently, VAC has been acknowledged for cutting effectively compared to a traditional cutting (TC) method. Advantages in VAC such as decreased cutting energy and surface roughness have been reported [16]. The 2D-VAC method is fundamentally similar to the elliptical vibration cutting (EVC) [17] as an alternative approach to 1D-VAC.…”

Section: Introductionmentioning

confidence: 99%

“…Recently, 2D-VAC has been acknowledged to effectively cut hard or difficult-to-cut material (e.g., Ti6Al4V [18] and Inconel 718 [19]) or even brittle material [20]. Also, 2D-VAC has been acknowledged to manufacture a textured surface pattern such as a microdimple [21], micro-groove [16], surface diffraction effect [22], and wettability pattern [23]. Therefore, 2D-VAC will become a promising metal removal process in the future and it is our motivation to explore this technique more.…”

Section: Introductionmentioning

confidence: 99%

Analytical, FEA, and experimental research of 2D-Vibration Assisted Cutting (2D-VAC) in titanium alloy Ti6Al4V

Kurniawan

Ahmed

Ali

et al. 2021

Int J Adv Manuf Technol

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In the 2D-Vibration Assisted Cutting (2D-VAC) method, the cutting tool shakes in a 2-dimensional approach because of superimposed high-frequency modulation. This high-frequency modulation effect creates a displacement at a tiny scale of micrometers and causes an escalation in the resultant cutting speed. Consequently, 2D-VAC has superior advantages compared to traditional cutting (TC). This manuscript describes research on 2D-VAC that focuses on modeling cutting forces (mathematical model) and finite element analysis (FEA) results. The FEA results are focused on the von Mises stress, plastic strain, cutting force, cutting temperature, and residual stress. In addition, an experiment for the chip formation, microstructure layer, and micro-hardness was also analyzed in this study. According to the modeling results, the cutting force has a comparable pattern to the FEA results. The stress contour result confirms that the 2D-VAC method has lower stress than that in the TC method during tool retraction mode. Additionally, the plastic strain in the 2D-VAC method can be higher than that in the TC method. According to the temperature results, the peak temperature in the 2D-VAC could be higher than that in the TC method. The residual stress shows that there is a compressive effect. Thus, the compressive stress is higher than that in the TC method. Micro-hardness results confirmed that there is not too much change from the original surface in the 2D-VAC method. The result of micro-structure morphology also confirmed that there is a significant shear deformation flow in case of the TC method, although less occurs in the 2D-VAC method.

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“…High frequency periodic separation has the advantages of small average force, high efficiency and high surface quality [2], [3]. The researches on ultrasonic machining cover wide ranges, such as the problem of the boundary damage of rotary ultrasonic machining [4], the investigation on machining performance of two-dimensional ultrasonic machining [5], the separation phenomenon of ultrasonic machining [6], and the application of anti-counterfeiting of surface microstructure through by two-dimensional ultrasonic machining [7]. Moreover, researchers have also done a number of studies on ultrasonic polishing.…”

Section: Introductionmentioning

confidence: 99%

A New Vibration Device Applied for Two-Dimensional Ultrasonic Polishing of Biomaterials

Lin

Yan

et al. 2019

IEEE Access

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For the research of the performance of two-dimensional ultrasonic polishing (TDUP) on the biomaterials, a new vibration device was designed. Meanwhile, our aim is to study the mechanism of multiangle polishing to cope with the complex structure of biomaterials. The device is composed of piezoelectric rings, asymmetric transformer, ultrasonic generator, and so on. The structural dimension parameters were optimized by finite element analysis, and especially the groove size on the transformer was discussed in detail. Two kinds of experiments had been conducted to test the performance of the proposed device, including impedance analysis experiments and amplitudes measurement experiments. Furthermore, a mechanical model to explain the principle of the multiangle polishing was set up, which could assist to analyze the influence of different polishing angles in terms of machining. Finally, the machining experiments and multiangle polishing experiments were carried out to verify the effectiveness of the device. Compared with traditional mechanical polishing, the surface roughness is reduced from 235 nm to 140 nm. The results of multiangle polishing experiments indicate that the surface quality of biomaterials will be prominently affected by different polishing angles. In addition, the polishing mechanism will transform owing to the inversion of the normal velocity during the polishing process with the angle increasing. The surface morphology will also be affected. It has been proven that the experimental results agree with the model well.

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Experimental and analytical study of ultrasonic elliptical vibration cutting on AISI 1045 for sustainable machining of round-shaped microgroove pattern

Cited by 41 publications

References 63 publications

Experimental Investigation on Micro-Groove Manufacturing of Ti-6Al-4V Alloy by Using Ultrasonic Elliptical Vibration Assisted Cutting

Experimental Investigation on Micro-Groove Manufacturing of Ti-6Al-4V Alloy by Using Ultrasonic Elliptical Vibration Assisted Cutting

Analytical, FEA, and experimental research of 2D-Vibration Assisted Cutting (2D-VAC) in titanium alloy Ti6Al4V

A New Vibration Device Applied for Two-Dimensional Ultrasonic Polishing of Biomaterials

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