Review of ultrasonic vibration-assisted machining in advanced materials

Yang, Zhichao; Zhu, Lida; Zhang, Guixiang; Ni, Chenbing; Lin, Bin

doi:10.1016/j.ijmachtools.2020.103594

Cited by 431 publications

(127 citation statements)

References 232 publications

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“…Surface roughness has an important influence on the service life, fatigue life and work efficiency of a machined workpiece and is influenced itself by the workpiece’s material properties, chatter, machining parameters, etc., [ 30 , 31 , 32 , 33 ]. The effects of dry micro cutting parameters on three-dimensional surface roughness parameters, including S a and S q , were investigated.…”

Section: Resultsmentioning

confidence: 99%

Experimental Investigation on Machinability of Aluminum Alloy during Dry Micro Cutting Process Using Helical Micro End Mills with Micro Textures

et al. 2020

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Aluminum alloy material is widely used in the electronics, weapons, aviation and aerospace industries, due to its medium strength, good corrosion resistance, good toughness and excellent oxidation properties. With the trend of product miniaturization, micro cutting has become the mainstream technique for fabricating micro parts and components, so it is very meaningful and vital to work on removing the cutting fluid from the micro cutting process and make it totally sustainable and eco-friendly. In this work, an attempt has been made to fabricate micro textures onto the rear surface of helical micro end mills with diameters of less than 1 mm. Micro textures in the form of grooves were fabricated using a noncontact low speed wire electrical discharge turning technique. Dry micro cutting experiments were carried out on an aluminum alloy material using helical micro end mills with micro textures and the dry micro cutting surface quality and tool wear have been investigated. The influence of dry micro cutting parameters on the surface roughness parameters were also investigated. Experimental results showed that the Sa and Sq can be reduced to be about 1.56 μm and 2.08 μm, respectively. Contrasting results indicate that the implantation of micro textures does not deteriorate the dry micro cutting surface but improves the machined surface consistency of an aluminum alloy workpiece. The tool wear on helical micro end mills with micro textures involved in the dry micro cutting process of Al 6061 mainly include rear frictional wear, oxidation wear and diffusion wear.

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Section: Resultsmentioning

confidence: 99%

Experimental Investigation on Machinability of Aluminum Alloy during Dry Micro Cutting Process Using Helical Micro End Mills with Micro Textures

et al. 2020

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“…Resonant EVC vibrators can obtain ultrasonic operational frequency [25,26] and large vibration amplitude over tens of micrometres [27] as a result of the high energy efficiency of the resonant mode. However, resonant EVC devices can only work under a fixed frequency (i.e., resonant frequency) and therefore can only machine microstructures with a fixed wavelength and height [28,29]. By contrast, nonresonant EVC devices with tunable operational frequency and vibration amplitude emerged to overcome the problems of resonant devices.…”

Section: Introductionmentioning

confidence: 99%

A high-frequency non-resonant elliptical vibration-assisted cutting device for diamond turning microstructured surfaces

Wang

Luo

Liu

et al. 2021

Int J Adv Manuf Technol

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In recent years, research has begun to focus on the development of non-resonant elliptical vibration-assisted cutting (EVC) devices, because this technique offers good flexibility in manufacturing a wide range of periodic microstructures with different wavelengths and heights. However, existing non-resonant EVC devices for diamond turning can only operate at relatively low frequencies, which limits their machining efficiencies and attainable microstructures. This paper concerns the design and performance analysis of a non-resonant EVC device to overcome the challenge of low operational frequency. The structural design of the non-resonant EVC device was proposed, adopting the leaf spring flexure hinge (LSFH) and notch hinge prismatic joint (NHPJ) to mitigate the cross-axis coupling of the reciprocating displacements of the diamond tool and to combine them into an elliptical trajectory. Finite element analysis (FEA) using the mapped meshing method was performed to assist the determination of the key dimensional parameters of the flexure hinges in achieving high operational frequency while considering the cross-axis coupling and modal characteristics. The impact of the thickness of the LSFH on the sequence of the vibrational mode shape for the non-resonant EVC device was also quantitatively revealed in this study. Moreover, a reduction in the thickness of the LSFH can reduce the natural frequency of the non-resonant EVC device, thereby influencing the upper limit of its operational frequency. It was also found that a decrease in the neck thickness of the NHPJ can reduce the coupling ratio. Experimental tests were conducted to systematically evaluate the heat generation, cross-axis coupling, modal characteristics and diamond tool’s elliptical trajectory of a prototype of the designed device. The test results showed that it could operate at a high frequency of up to 5 kHz. The cross-axis coupling ratio and heat generation of the prototype are both at an acceptable level. The machining flexibility and accuracy of the device in generating microstructures of different wavelengths and heights through tuning operational frequency and input voltage have also been demonstrated via manufacturing the micro-dimple arrays and two-tier microstructured surfaces. High-precision microstructures were obtained with 1.26% and 10.67% machining errors in wavelength and height, respectively.

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“…Moreover, Liu et al [17] investigated the mechanisms of the rotary ultrasonic elliptical machining on surface integrity of Ti6Al4V and found that surface integrity was improved due to the compressive residual stress, work hardening, and plastic deformation in the machined workpiece surface. In general, after reviewing a variety of research on UAM, it is concluded that the UAM methods demonstrate substantially improved machinability over CM in machining of difficult-to-machine materials, such as increased tool life, reduced cutting force, and improved surface integrity [18]. The significantly improved machinability of UAM over CM mainly results from the reduction of the uncut chip thickness and intermittent contact between the workpiece and cutting tool, which extensively works for both brittle and ductile materials.…”

Section: Introductionmentioning

confidence: 99%

Surface Integrity of Ultrasonically-Assisted Milled Ti6Al4V Alloy Manufactured by Selective Laser Melting

Guo

Jiang

et al. 2021

Chin. J. Mech. Eng.

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The Ti6Al4V parts produced by the existing selective laser melting (SLM) are mainly confronted with poor surface finish and inevitable interior defects, which substantially deteriorates the mechanical properties and performances of the parts. In this regard, ultrasonically-assisted machining (UAM) technique is commonly introduced to improve the machining quality due to its merits in increasing tool life and reducing cutting force. However, most of the previous studies focus on the performance of UAM with ultrasonic vibrations applied in the tangential and feed directions, whereas few of them on the impact of ultrasonic vibration along the vertical direction. In this study, the effects of feed rate on surface integrity in ultrasonically-assisted vertical milling (UAVM) of the Ti6Al4V alloy manufactured by SLM were systemically investigated compared with the conventional machining (CM) method. The results revealed that the milling forces in UAVM showed a lower amplitude than that in CM due to the intermittent cutting style. The surface roughness values of the parts produced by UAVM were generally greater than that by CM owing to the extra sinusoidal vibration textures induced by the milling cutter. Moreover, the extra vertical ultrasonic vibration in UAVM was beneficial to suppressing machining chatter. As feed rate increased, surface microhardness and thickness of the plastic deformation zone in CM raised due to more intensive plastic deformation, while these two material properties in UAVM were reduced owing to the mitigated impact effect by the high-frequency vibration of the milling cutter. Therefore, the improved surface microhardness and reduced thickness of the subsurface deformation layer in UAVM were ascribed to the vertical high-frequency impact of the milling cutter in UAVM. In general, the results of this study provided an in-depth understanding in UAVM of Ti6Al4V parts manufactured by SLM.

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Review of ultrasonic vibration-assisted machining in advanced materials

Cited by 431 publications

References 232 publications

Experimental Investigation on Machinability of Aluminum Alloy during Dry Micro Cutting Process Using Helical Micro End Mills with Micro Textures

Experimental Investigation on Machinability of Aluminum Alloy during Dry Micro Cutting Process Using Helical Micro End Mills with Micro Textures

A high-frequency non-resonant elliptical vibration-assisted cutting device for diamond turning microstructured surfaces

Surface Integrity of Ultrasonically-Assisted Milled Ti6Al4V Alloy Manufactured by Selective Laser Melting

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