Rotary ultrasonic machining of carbon fiber–reinforced plastic composites: effects of ultrasonic frequency

Wang, Hui; Hu, Yingbin; Cong, Weilong; Burks, Anthony R.

doi:10.1007/s00170-019-04084-4

Cited by 24 publications

(3 citation statements)

References 45 publications

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“…Existing ultrasonic vibration processing devices are limited by power and other factors, making it difficult to achieve ultrasonic vibration on large, heavy, and complex materials and workpiece shapes, which affects their industrial application. Wang et al [98,99] used both workpiece vibration and tool vibration to achieve three-dimensional rotational ultrasonic vibration for machining CFRP materials. Two ultrasonic power sources were used to drive the workpiece horizontal ultrasonic vibration and tool vertical vibration, which were superimposed with the grinding rotational motion to form a special three-dimensional abrasive grain motion trajectory, as shown in figure 10.…”

Section: Workpiece Ultrasonic Vibration-assisted Grindingmentioning

confidence: 99%

Nontraditional energy-assisted mechanical machining of difficult-to-cut materials and components in aerospace community: a comparative analysis

Zhao,

Ding

et al. 2024

Int. J. Extrem. Manuf.

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Difficult-to-cut materials such as titanium alloys, high-temperature alloys, metal/ceramic/polymer-matrix composites, hard and brittle materials, as well as geometrically complex components such as thin-walled structures, micro channels and complex surfaces, are widely used in aerospace community. Mechanical machining is the main material removal process and responsible for the vast majority of material removal for aerospace components. Nevertheless, it encounters many problems in terms of severe and rapid tool wear, low machining efficiency, and deteriorated surface integrity. Nontraditional energy-assisted mechanical machining is a hybrid process in which nontraditional energies, e.g., vibration, laser, electric, etc., are applied to improve the machinability of local material and decrease burden of mechanical machining. It provides a feasible and promising way for improving machinability and surface quality, reducing process forces, and prolonging tool life, etc. However, systematic reviews of this technology are lacking with respect to the current research status and development direction. This paper reviews recent progress in nontraditional energy-assisted mechanical machining of difficult-to-cut materials and components in aerospace community. It focuses on the processing principles, material responses under nontraditional energy, resultant forces and temperatures, material removal mechanisms and applications of these processes including vibration-, laser-, electric-, magnetic-, chemical-, cryogenic cooling-, and hybrid nontraditional energies-assisted mechanical machining. Eventually, a comprehensive summary of the principles, advantages and limitations for each hybrid process is provided, and future perspectives on forward design, device development and sustainability of nontraditional energy-assisted mechanical machining processes are discussed.

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Section: Workpiece Ultrasonic Vibration-assisted Grindingmentioning

confidence: 99%

Nontraditional energy-assisted mechanical machining of difficult-to-cut materials and components in aerospace community: a comparative analysis

Zhao,

Ding

et al. 2024

Int. J. Extrem. Manuf.

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show abstract

“…Wang et al. [12,13] also successfully extended RUAD method in which vibration is applied along the tool axis to improve the machining of the CFRPs surfaces, whereas the risk of delamination damage increases since the cooling fluid with a certain pressure is pumped through core drill. Thomas et al [14] investigated the drill bit's vibrational characteristic, the experimental and simulation results showed that there are several well-documented advantages of RUAD over CD techniques such as reduction in thrust forces and torque, better surface finish, low tool wear and elimination/reduction in burr formation.…”

Section: Introductionmentioning

confidence: 99%

Experimental and scale-span numerical investigations in conventional and longitudinal torsional coupled rotary ultrasonic–assisted drilling of CFRPs

Liu

Pan

et al. 2021

Int J Adv Manuf Technol

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Longitudinal torsional coupled rotary ultrasonic assisted drilling (LTC-RUAD) technology is introduced to improve the surface roughness of the hole wall and solve the tear, burr and delamination of carbon fiber reinforced polymers (CFRPs) induced by large thrust force and torque during conventional drilling (CD). An experiment and scale-span numerical investigation of drilling CFRPs was presented for both CD and LTC-RUAD process in this study. A drilling experimental platform using LTC-RUAD was built via a novel independently designed and manufactured LTC-RUAD vibration actuator, while the drilling experiments involving T700S-12K/YP-H26 CFRPs specimens with different process parameters were carried out by adopting the different ultrasonic vibration amplitude (UVA) in the longitudinal and torsional directions. Then, a three-dimensional (3D) scale-span FE simulation model of CD and LTC-RUAD which applied the different UVA using tapered drill-reamer (TDR) are developed to find more details about the effects of machining quality of the holes.Experimental and simulation results revealed that the maximum average thrust force reduction is observed to be as high as 30% under certain drilling conditions, and the maximum average thrust force and the delamination factor of the drilled hole shows a "concave" trend with the increase of the UVA. The quality at the exit of the drilled hole is the best when adopting Sr=2000rpm, Sf=0.01mm/rev, Alon=7.02μm and Ator=9.29μm in LTC-RUAD. The delamination factor is only 0.054. The damage factors are reduced by 69.67% compared with CD.

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“…Cong et al [11] employed the similar RUAD method to drill CFRPs laminate to prevent clog and improve the hole's quality. Wang et al [12,13] also successfully extended RUAD method in which vibration is applied along the tool axis to improve the machining of the CFRPs surfaces, whereas the risk of delamination damage increases since the cooling fluid with a certain pressure is pumped through core drill. Thomas et al [14] investigated the drill bit's vibrational characteristic, the experimental and simulation results showed that there are several well-documented advantages of RUAD over CD techniques such as reduction in thrust forces and torque, better surface finish, low tool wear and elimination/reduction in burr formation.…”

Section: Introductionmentioning

confidence: 99%

Experimental and Scale-span Numerical Investigations in Conventional and Longitudinal Torsional Coupled Rotary Ultrasonic Assisted Drilling of CFRPs

Liu

et al. 2021

Preprint

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Longitudinal torsional coupled rotary ultrasonic assisted drilling (LTC-RUAD) technology is introduced to improve the surface roughness of the hole wall and solve the tear, burr and delamination of carbon fiber reinforced polymers (CFRPs) induced by large thrust force and torque during conventional drilling (CD). An experiment and scale-span numerical investigation of drilling CFRPs was presented for both CD and LTC-RUAD process in this study. A drilling experimental platform using LTC-RUAD was built via a novel independently designed and manufactured LTC-RUAD vibration actuator, while the drilling experiments involving T700S-12K/YP-H26 CFRPs specimens with different process parameters were carried out by adopting the different ultrasonic vibration amplitude (UVA) in the longitudinal and torsional directions. Then, a three-dimensional (3D) scale-span FE simulation model of CD and LTC-RUAD which applied the different UVA using tapered drill-reamer (TDR) are developed to find more details about the effects of machining quality of the holes. Experimental and simulation results revealed that the maximum average thrust force reduction is observed to be as high as 30% under certain drilling conditions, and the maximum average thrust force and the delamination factor of the drilled hole shows a "concave" trend with the increase of the UVA. The quality at the exit of the drilled hole is the best when adopting Sr=2000rpm, Sf=0.01mm/rev, Alon=7.02μm and Ator=9.29μm in LTC-RUAD. The delamination factor is only 0.054. The damage factors are reduced by 69.67% compared with CD.

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Rotary ultrasonic machining of carbon fiber–reinforced plastic composites: effects of ultrasonic frequency

Cited by 24 publications

References 45 publications

Nontraditional energy-assisted mechanical machining of difficult-to-cut materials and components in aerospace community: a comparative analysis

Nontraditional energy-assisted mechanical machining of difficult-to-cut materials and components in aerospace community: a comparative analysis

Experimental and scale-span numerical investigations in conventional and longitudinal torsional coupled rotary ultrasonic–assisted drilling of CFRPs

Experimental and Scale-span Numerical Investigations in Conventional and Longitudinal Torsional Coupled Rotary Ultrasonic Assisted Drilling of CFRPs

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