Finite element simulation of ultrasonic-assisted machining: a review

Lotfi, Mohammad; Âkbari, Jafar

doi:10.1007/s00170-021-07205-0

Cited by 22 publications

(6 citation statements)

References 80 publications

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“…Machining forces can be reduced in vibration-assisted machining process, and tool life can be increased. Also, this leads to better surface finish, improved form accuracy and zero burr formation [1][2][3]. A crucial component of the ultrasonic vibration-assisted machining system is an ultrasonic transducer.…”

Section: Introductionmentioning

confidence: 99%

Design of a novel 2D ultrasonic transducer for 2D high-frequency vibration–assisted micro-machining

Satpute

Huo

Hedley

et al. 2023

Int J Adv Manuf Technol

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Ultrasonic vibration–assisted machining (VAM) is a process in which a tool or workpiece is vibrated using ultrasonic frequency small-amplitude vibrations to improve cutting performance, and an ultrasonic transducer usually generates these vibrations. This study investigates how two-dimensional vibrations are generated using axially polled piezoceramics. Modifying the wave propagation in geometric ways by creating a notch at the front mass, the longitudinal response excited by the axially polled piezoceramic discs can be converted into combined longitudinal and bending vibrations at the transducer front mass. Finite element analysis (FEA) software COMSOL is used to study wave propagation, and ANSYS is used to optimize the transducer’s mechanical structure, while an equivalent circuit approach is used to analyze the electrical impedance spectra and confirm its resonance frequency. An experimental analysis of impedance response and amplitude of generated vibrations using the novel 2D ultrasonic transducer is conducted to validate the numerical and analytical results, which shows that resonance frequency results are in very good agreement with the theoretical model. Finally, the proposed design is validated by preliminary test results that demonstrate its performance and principles.

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Section: Introductionmentioning

confidence: 99%

Design of a novel 2D ultrasonic transducer for 2D high-frequency vibration–assisted micro-machining

Satpute

Huo

Hedley

et al. 2023

Int J Adv Manuf Technol

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“…needed to be studied. Researchers have developed 2D, 12–14 3D FEM 15–17 models to study the effect of cutting forces, residual stresses, and tool tip temperature for various softer materials and reported the reduction in cutting forces, 15,18 compressive nature residual stress, 19 and reduced temperature on the tooltip. 13…”

Section: Introductionmentioning

confidence: 99%

Understanding tool chip interaction through experimental and numerical analysis during vibration assisted turning of AISI D3 steel

Dutta,

Bartarya

2023

Proceedings of the Institution of Mechanical Engineers, Part C:

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Vibration Assisted Turning (VAT) is a hybrid machining process where the material is machined with the help of a tool vibrating at ultrasonic frequency. VAT results in significant changes in process characteristics compared to conventional machining, like reducing the machining forces and tool wear. The chips produced during the machining operation can provide valuable insight into the process characteristics like machining zone temperature, friction at the tool-chip interface and chip load that primarily alter the process performance. One can understand and have a better control on the machining process performance by studying the formation of these chips and the tool-chip interaction. The work presents an experimental and numerical study to analyze the chip formation during VAT while machining AISI D3 steel. The chips formed while machining at different vibration amplitudes were observed to be of different colors, widths, and thicknesses. These were found to correlate to the forces generated and the surface integrity produced. A decrease in the chip width and thickness was observed with an increase in the amplitude that helps to reduce the chip load and hence forces. Also, the temperature at the machining zone increased with an increase in amplitude as seen from different color of chips produced and carbon content of the chip. The numerical model, developed to analyze the effect of the vibration amplitude on the contact pressure at the chip-tool interface, showed that the average contact pressure reduced upon applying ultrasonic vibration to the tool, thereby reducing the coefficient of friction and frictional forces. Also, with increase in vibration amplitude, the coefficient of friction was found increasing but it still remained lower than that in conventional turning. The study would help to understand the reduction the overall machining forces and chip morphology and thereby to have a better control on the process performance.

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“…The ultrasonic vibration equipment and ultrasonic-vibration-assisted cutting mechanisms and equipment include one-dimensional vibrations and multidimensional vibrations, and they have been widely studied by scholars worldwide. At present, the ultrasonic-vibration-assisted cutting method has been widely used in the turning, milling, and drilling of various workpiece materials, such as metal, ceramics, and composite materials [14][15][16][17][18]. In addition to the above energy fields, the flame, chemical, and ionic energy fields have also been studied to aid in the cutting process of various materials.…”

Section: Introductionmentioning

confidence: 99%

Magnetic-Field-Assisted Scratching Process of Single-Crystal Copper

Wu,

Zhang,

Sun

et al. 2023

Micromachines

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Energy-field-assisted cutting exhibits excellent ability to reduce cutting force and improve machining quality. In this study, a magnetic field was applied in an innovative way to aid in the cutting process, and magnetic-field-assisted scratching experiments of single-crystal copper were carried out. It was found that magnetic-field-assisted scratching increased the actual scratching force due to the additional Lorentz force in the cutting process. However, the friction coefficient of the magnetic-field-assisted scratching was reduced by 19.4% due to the tribological modification effect on tool/chip contact. Meanwhile, magnetic-field-assisted scratching was conducive to decreasing the degree of chip deformation, reducing microburrs on the machined surface, and obtaining a surface roughness reduction of an average of 26.8%. The possible reason for this effect was that the presence of a magnetic field in the cutting process promoted the dislocation slip of metal materials. The results indicated that magnetic-field-assisted cutting improves the machinability in the metal cutting process.

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Finite element simulation of ultrasonic-assisted machining: a review

Cited by 22 publications

References 80 publications

Design of a novel 2D ultrasonic transducer for 2D high-frequency vibration–assisted micro-machining

Design of a novel 2D ultrasonic transducer for 2D high-frequency vibration–assisted micro-machining

Understanding tool chip interaction through experimental and numerical analysis during vibration assisted turning of AISI D3 steel

Magnetic-Field-Assisted Scratching Process of Single-Crystal Copper

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