Experimental study on ultrasonic elliptical vibration cutting of hardened steel using PCD tools

Zhang, Xinquan; Kumar, A. Senthil; Rahman, Mustafizur; Nath, Chandra; Liu, Kui

doi:10.1016/j.jmatprotec.2011.05.015

Cited by 114 publications

(30 citation statements)

References 15 publications

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“…Direct machining of these materials is cost-effective, and obtaining their high-quality surfaces is always a concern in the manufacturing industry owing to the high tool wear [25,71]. Although diamond tools have been widely used in cutting non-ferrous materials for high-quality mirror surfaces [71][72][73][74], it cannot be used to cut ferrous materials because of the strong chemical affinity of diamond (carbon) with iron causing excessive tool wear [75][76][77]. However, Kumabe [23] reported that with the aid of ultrasonic vibration, the diamond tools could be used to cut steels.…”

Section: Hard-to-machine Steelmentioning

confidence: 99%

“…Moriwaki and Shamoto [25,33] then performed the CDVA and EVA cutting of stainless steel and hardened steel with single crystal diamond (SCD) tools, and confirmed that the UVA method was indeed superior in the machining of ferrous materials, i.e., low cutting force, high quality surface finish and long tool life. In order to reduce production cost, Zhou et al [72] and Zhang et al [74] investigated the EVA cutting with polycrystalline Fig. 4 Experimental results of a thrust cutting force [36], b shape error [36], and c burr formation [64] in different cutting modes Ultrasonic vibration-assisted machining: principle, design and application diamond (PCD) tools.…”

Section: Hard-to-machine Steelmentioning

confidence: 99%

See 1 more Smart Citation

Ultrasonic vibration-assisted machining: principle, design and application

Zhang

2015

Adv. Manuf.

141

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Ultrasonic vibration-assisted (UVA) machining is a process which makes use of a micro-scale high frequency vibration applied to a cutting tool to improve the material removal effectiveness. Its principle is to make the tool-workpiece interaction a microscopically non-monotonic process to facilitate chip separation and to reduce machining forces. It can also reduce the deformation zone in a workpiece under machining, thereby improving the surface integrity of a component machined. There are several types of UVA machining processes, differentiated by the directions of the vibrations introduced relative to the cutting direction. Applications of UVA machining to a wide range of workpiece materials have shown that the process can considerably improve machining performance. This paper aims to provide a comprehensive discussion and review about some key aspects of UVA machining such as cutting kinematics and dynamics, effect of workpiece materials and wear of cutting tools, involving a wide range of workpiece materials including metal alloys, ceramics, amorphous and composite materials. Some aspects for further investigation are also outlined at the end.

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Section: Hard-to-machine Steelmentioning

confidence: 99%

Section: Hard-to-machine Steelmentioning

confidence: 99%

Ultrasonic vibration-assisted machining: principle, design and application

Zhang

2015

Adv. Manuf.

141

View full text Add to dashboard Cite

show abstract

“…This technology is one of potential methods to attain efficient surface machining of hardened steel [8], wolfram carbide [9,10], carbon fiber reinforced plastics [11], oxygen free copper [12], and glass and ceramics [13]. By applying EVC during machining, the cutting force reduction is observed [8].…”

Section: Introductionmentioning

confidence: 99%

“…Otherwise, high-quality surface finish [9] and long tool life [13] can be obtained, and the regenerative chatter can be suppressed effectively [14,15].…”

Section: Introductionmentioning

confidence: 99%

Analysis and modeling of force in orthogonal elliptical vibration cutting

Bai

Sun

Gao

et al. 2015

Int J Adv Manuf Technol

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This paper aims to reveal the material removal mechanisms of the elliptical vibration cutting (EVC) and present the predicted model of orthogonal cutting force. Further study of mechanism will be helpful to explain the phenomena that EVC can reduce the cutting force, lower cutting temperature, and improve the surface integrity. In each overlapping EVC cycle, almost all the parameters are time-varying, of which two important factors are focused: (i) transient thickness of cut and (ii) transient shear angle. The analysis model simplified the complex process of the EVC as conventional cutting (CC) which considering two transient variables. This paper presents a non-equidistant shear zone model to predict the shear angle, tool-chip friction angle, and shear stress in CC under the same conditions of the EVC. Then, the transient thickness of cut and transient shear angle are investigated. Thus, an analytical model of the force in EVC is proposed. The model is available to predict the cutting force of the EVC accurately without any experimental parameters in CC. In addition, experimental results available in the literature are conducted for comparison, which are in well agreement with the analysis model

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“…1,2 In the two-dimensional ultrasonic vibration cutting (TDUVC), cutting tool is no longer the high-frequency vibration with single direction round, but the trajectory of the elliptical vibration cutting the workpiece 3,4 effectively avoids the long time friction between tool flank face and the machined surface in traditional ultrasonic vibration, alleviates the tipping breakage of the tool and adverse impacts on the processing quality of the workpiece and effectively reduces the cutting force, improves the surface machining precision, prolongs tool life, and it is suitable for precision and ultra-precision processing of difficult-to-machine materials. [5][6][7] Laser-assisted cutting (LAC) uses high-power energy emitted from the laser device focusing and irradiating on the surface to be machined in a certain distance away from the tip, and the material is heated to a certain temperature instantly, makes the material workability improved under high temperature, improves the plasticity of materials, and reduces the cutting force and tool wear. 8,9 And the cutting of difficult-to-machine material can be achieved in ductile field; yield strength is reduced to below the fracture strength, so that avoiding cracks appearing in the process and improving the machining efficiency and surface quality.…”

Section: Introductionmentioning

confidence: 99%

Research on characteristics of tool wear in laser heating and ultrasonic vibration cutting of tungsten carbide

Jiao

Niu

Zhang

et al. 2016

Advances in Mechanical Engineering

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Ultra-precision machining of tungsten carbide (YG10) can be realized under the combined assistance of laser heating and two-dimensional ultrasonic vibration. In order to study the wear mechanism of PCBN cutting tool and its influence on cutting process, the cutting tool wear condition and the evolution process of flank wear are observed, and the wear mechanism of PCBN cutting tools is analyzed under the combined effects of laser and ultrasonic vibration. Compared with the traditional cutting, the laser-assisted cutting, the two-dimensional ultrasonic vibration cutting, it is studied that the effect of tool wear on the machining precision, machining quality, and cutting force with the change in length of cut in laser heating and two-dimensional ultrasound composite-assisted cutting (LUAC) and the tool wear characteristics are analyzed under the special coupled thermo-force. The research results show that the LUAC can effectively alleviate tool wear, improve dimensional precision and surface quality, and reduce cutting forces.

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Experimental study on ultrasonic elliptical vibration cutting of hardened steel using PCD tools

Cited by 114 publications

References 15 publications

Ultrasonic vibration-assisted machining: principle, design and application

Ultrasonic vibration-assisted machining: principle, design and application

Analysis and modeling of force in orthogonal elliptical vibration cutting

Research on characteristics of tool wear in laser heating and ultrasonic vibration cutting of tungsten carbide

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