Rotary Ultrasonic Machining of Alumina Ceramic: An Experimental Investigation of Tool Path and Tool Overlapping

Abdo, Basem M. A.; El-Tamimi, Abdualziz; Nasr, Emad Abouel

doi:10.3390/app10051667

Cited by 9 publications

(10 citation statements)

References 35 publications

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“…To obtain the mechanical states corresponding to the five states, the simulation will be performed until the material of the flanging lip has incurred large damage and been squeezed out of the housing chamfer [20][21][22]. "State 1" is the state where the flanging lip just comes into contact with the roller, which is the simulation start time.…”

Section: Equivalent Stress Analysismentioning

confidence: 99%

Research on Multi-Stage Composite Loading Process Control Method for Roller Staking of Self-Lubricating Spherical Plain Bearings

et al. 2021

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The staking quality of Self-lubricating Spherical Plain Bearings (SSPBs) directly affects the safety of aircraft and the service life of bearings. Reliable loading process control methods and precise process parameter indexes will come into the creation of efficacious staking quality. Therefore, this paper aims to analyze the mechanical state of the roller staking process and give a load control method and corresponding parameter indexes for the high-quality roller staking process. First, based on the analysis of quality inspection requirements, five states of the deformation degree of the flanging lip of the V groove during the roller staking process were proposed, and their relationship with the requirements was studied. Then, the mechanical states corresponding to the five deformation states of the flanging lip deformation were obtained by numerical simulation, and the feeding displacement was determined. Meanwhile, a Multi-Stage Composite Loading (MSCL) process control method was first proposed to control the material damage of the flanging lip, i.e., the rotate speed of the roller tool was constant during the roller staking process, and the displacement–time control was adopted first; when the staking load reaches a staking value, the force–time control was used to make the staking quality meet the requirements. Finally, the staking quality of the MSCL method was verified though the test. The research shows that the feeding displacement needs to be added to the requirements, and the recommended value is 0.5–0.6 times of the V groove depth. A good surface quality and non-material-damage of the flanging lip is more likely to be obtained by the MSCL process control method. The research reveals the formation mechanism of process deformation, and gives more precise process control indexes. At the same time, it provides a theoretical reference for more reliable technical standards.

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Section: Equivalent Stress Analysismentioning

confidence: 99%

Research on Multi-Stage Composite Loading Process Control Method for Roller Staking of Self-Lubricating Spherical Plain Bearings

et al. 2021

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“…High hardness, electrical resistivity, wear resistance and corrosion resistance has made Al 2 O 3 as an appropriate candidate for cutting tool material in hard machining of difficult to cut materials such as alloy steels. [1][2][3] Due to these elevated properties, the machinability of Al 2 O 3 is low; hence particular methods must be utilized for processing this material.…”

Section: Introductionmentioning

confidence: 99%

Drilling of Al₂O₃ ceramic using ultrasonic assisted electrochemical discharge machining process

Bagheri

Sayadi

Etefagh

et al. 2022

Proceedings of the Institution of Mechanical Engineers, Part E:

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Alumina is one of the most important ceramic materials in the industry due to its advantageous properties, such as electrical resistivity and high hardness. The machining of this material encounters several difficulties, and it is usually machined using non-traditional machining processes. Among these processes, ultrasonic-assisted electrochemical discharge machining has been widely used for glass machining. However, this machining process is expected to be accompanied by acceptable results in the case of alumina. Therefore, in this study, the effects of process parameters such as ultrasonic vibration amplitude, voltage, pulse-on time, and pulse-off time on material removal rate, depth, overcut, and taper angle have been experimentally studied in the machining of alumina. The results revealed that hole depth increased up to 52% using ultrasonic vibrations with an amplitude of 34 µm.

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“…Ultrasonic vibration has been applied to various manufacturing machines such as bonding, welding, drilling, and cutting machines by resonating a tool at ultrasonic frequency to assist in the manufacturing process [1][2][3][4][5][6][7][8][9]. Ultrasonic machining has many advantages over the conventional machining process.…”

Section: Introductionmentioning

confidence: 99%

Optimal Design and Experimental Verification of Ultrasonic Cutting Horn for Ceramic Composite Material

et al. 2021

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We developed and optimized a block-type ultrasonic horn that can be used for cutting hard materials. The proposed block-type sonotrode consists of an aluminum horn and a tungsten carbide blade to increase the cutting of hard materials. We designed an initial ultrasonic block horn that has double slots and an exponential stepped profile. We developed a finite element model of the initial model and analyzed the characteristics of natural frequency and displacement. We formulated a DOE table and response surface to perform sensitivity analysis and analyze the correlation between the design variables and characteristics of the proposed block horn. The optimal ultrasonic block horn was derived via a multi-objective optimal design problem to maximize the amplitude uniformity of the proposed horn and frequency separation. We fabricated the optimal block horn and verified it experimentally. An ultrasonic cutting experiment was conducted to find the ultrasonic cutting force with hard ceramic composite materials. A cutting test with a conventional cutting machine under the same condition was also conducted to compare the cutting force. The proposed optimal ultrasonic cutter requires 70% less cutting force than the conventional cutter to cut a ceramic composite material and the cutting surface with the application of the proposed optimal ultrasonic cutter is much cleaner with no crack and delamination than that with the application of the conventional cutter.

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Rotary Ultrasonic Machining of Alumina Ceramic: An Experimental Investigation of Tool Path and Tool Overlapping

Cited by 9 publications

References 35 publications

Research on Multi-Stage Composite Loading Process Control Method for Roller Staking of Self-Lubricating Spherical Plain Bearings

Research on Multi-Stage Composite Loading Process Control Method for Roller Staking of Self-Lubricating Spherical Plain Bearings

Drilling of Al₂O₃ ceramic using ultrasonic assisted electrochemical discharge machining process

Optimal Design and Experimental Verification of Ultrasonic Cutting Horn for Ceramic Composite Material

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Rotary Ultrasonic Machining of Alumina Ceramic: An Experimental Investigation of Tool Path and Tool Overlapping

Cited by 9 publications

References 35 publications

Research on Multi-Stage Composite Loading Process Control Method for Roller Staking of Self-Lubricating Spherical Plain Bearings

Research on Multi-Stage Composite Loading Process Control Method for Roller Staking of Self-Lubricating Spherical Plain Bearings

Drilling of Al2O3 ceramic using ultrasonic assisted electrochemical discharge machining process

Optimal Design and Experimental Verification of Ultrasonic Cutting Horn for Ceramic Composite Material

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Product

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About

Drilling of Al₂O₃ ceramic using ultrasonic assisted electrochemical discharge machining process