Experimental study on ultrasonic use in dry creep-feed up-grinding of aluminum 7075 and Steel X210Cr12

Abdullah, Amir; Sotoodezadeh, Mohammad; Abedini, Rezvan; Fartashvand, Vahid

doi:10.1007/s12541-013-0027-9

Cited by 30 publications

(7 citation statements)

References 21 publications

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“…Abdullah et al [6]investigated the Influence of ultrasonic grinding on materials under creep feed conditions and found that the use of ultrasonic waves effectively reduces grinding forces. Additionally, materials with higher hardness experience a greater reduction in grinding forces, and ultrasonic vibration proves effective in minimizing occurrences of grinding burns.…”

Section: Introductionmentioning

confidence: 99%

Prediction method for residual stress evolution caused by rolling/sliding contact in ultrasonic vibration-assisted grinding

Ye,

Jun,

Tang

et al. 2024

Preprint

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Ultrasonic vibration-assisted grinding (UVAG) technology has advantages in improving part surface integrity. Currently, the calculation of residual stresses in UVAG typically relies on commercial finite element software. However, because commercial finite element software is not specialized for residual stress calculations, the computational efficiency could be higher, and the accuracy could be better. This paper proposes a semi-analytical residual stress prediction model that considers the Influence of ultrasonic vibration. This paper introduces a semi-analytical residual stress prediction model that considers the impact of ultrasonic vibration. The model calculates the grinding mechanical and thermal stress fields separately using contact mechanics and finite difference methods. Based on Hertz's contact theory and Timoshenko's thermoelastic theory, a correlation model is provided for the association between mechanical and thermal loads with the internal stresses in the workpiece. Subsequently, the residual stress field is solved by considering the thermal-mechanical coupling effects in UVAG. Ultrasonic-assisted grinding experiments were conducted using 12Cr2Ni4A alloy steel as the object, and the maximum error between the predicted residual stresses by the model and the measured residual stresses was 10.5%.In addition, the detailed discussion on the Influence of grinding parameters on residual stress reveals that reducing the grinding wheel speed can significantly increase surface compressive residual stress. The paper's research shows that the residual stress distribution obtained by the new residual stress calculation model is correct, and the calculation efficiency is high, providing a new method for predicting residual stress in UVAG.

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Section: Introductionmentioning

confidence: 99%

Prediction method for residual stress evolution caused by rolling/sliding contact in ultrasonic vibration-assisted grinding

Ye,

Jun,

Tang

et al. 2024

Preprint

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“…Abhimanyu et al [32,33] found that the ultrasonic vibration could avoid the plastic damage of the machined surface and improve the surface integrity under dry grinding. Amir et al [34] reported that the employment of ultrasonic vibrations into CG processes of X210Cr12 steel could avoid the damages of ground surface. However, the researches on the grinding performance of ultra-high strength steels after applying ultrasonic vibrations were rarely carried out and the associated material removal mechanism lacked in-depth study.…”

Section: Introductionmentioning

confidence: 99%

Study on grinding performance during ultrasonic vibration-assisted grinding ultra-high strength steels

Han,

Tang,

Ding

et al. 2023

Int J Adv Manuf Technol

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Super high-strength steel has an important demand in manufacturing key components inside gear transmission systems of heavy-duty helicopter owing to its superior comprehensive mechanical property. However, the high-performance machining of super high-strength steel is confronted with great challenges owing to the high cutting force, serious tool wear, and impoverished machining quality.Comparative trials in grinding ultra-high strength steel under conventional grinding (CG) and ultrasonic vibration-assisted grinding (UVAG) processes was conducted with white alumina (WA) and microcrystalline alumina (MA) wheels. Grinding performances, including grinding forces, force ratio, ground surface quality, and abrasive wheel morphologies were discussed in detail. Experimental resultsshow that the separation property between wheels and workpiece in UVAG process contributes to alter the material removal process, reducing the chip clogging and adhesion. In addition, the micro-fracture of abrasive grains can effectively improve the self-sharpening ability of abrasive wheels. UVAG possesses a shorter grinding scratch owing to the ultrasonic vibration than that of CG, which is bene cial to improve machining quality under the same wheel. Meanwhile, in comparison of WA wheels, MA wheels have the narrower grinding marks and better surface quality, which is due to the sharp edges produced by its higher strength, toughness and excellent self-sharpening.

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“…The performed literature survey reveals that ultrasound-assisted grinding is an effective method for machining hard and brittle materials. However, the ultrasonic vibration of many devices is superimposed on the workpiece, which is lack of process universality [18][19][20][21][22]. Even if the ultrasonic vibration is superimposed on the abrasive tools, the maximum diameter of abrasive tools is only 50mm [23][24][25][26][27].…”

Section: Introductionmentioning

confidence: 99%

Investigation of the longitudinal-flexural resonating spindle in ultrasound-assisted grinding of SiCp/Al composites

Qin

Zhu

et al. 2022

Int J Adv Manuf Technol

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Rotary ultrasonic machining is a cost-effective and precise machining method for hard and brittle materials. Aiming at processing SiCp/Al composites, a rotary ultrasonic grinding spindle is proposed in the present study. Expressions were established to calculate the displacement, rotation angle, bending moment, and shear force of the vibrating elements based on the Mindlin moderate plate theory. Combining continuous and boundary conditions of vibrating elements with the proposed expressions, the vibration model and frequency equation of longitudinal-exural resonating transformer with a large load were established. Then two transformers were designed according to the frequency equation. The resonant characteristics of the transformers were studied using nite element analysis, impedance analysis, and ultrasonic resonance experiments. The obtained results show that the maximum deviation between the resonant frequency and the design frequency of the transformers was 4.95%. Moreover, the maximum deviation of the positions of the pitch circles was 6.51%. It is concluded that the proposed designs have high accuracy. Finally, the orthogonal single-factor experiments of SiCp/Al composites were performed with and without ultrasound. The obtained resultsshow that introducing ultrasonic vibrations signi cantly reduces the grinding force and the surface roughness while improving the surface quality of the SiCp/Al workpiece. The present study is expected to provide experimental fundamentals to further improve the structure of the grinding spindle, optimize process variables of ultrasound-assisted grinding, and improve the processing e ciency.

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Experimental study on ultrasonic use in dry creep-feed up-grinding of aluminum 7075 and Steel X210Cr12

Cited by 30 publications

References 21 publications

Prediction method for residual stress evolution caused by rolling/sliding contact in ultrasonic vibration-assisted grinding

Prediction method for residual stress evolution caused by rolling/sliding contact in ultrasonic vibration-assisted grinding

Study on grinding performance during ultrasonic vibration-assisted grinding ultra-high strength steels

Investigation of the longitudinal-flexural resonating spindle in ultrasound-assisted grinding of SiCp/Al composites

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