Rotary ultrasonic machining of CFRP composites: A study on power consumption

Abstract

Carbon fiber reinforced plastic (CFRP) composites are very difficult to machine. A large number of holes need to be drilled in CFRP for many applications. Therefore, so it is important to develop cost-effective drilling processes. CFRP has been drilled by rotary ultrasonic machining (RUM) successfully. The literature has reports about the effects of input variables on output variables (including cutting force, torque, surface roughness, tool wear, and workpiece delamination) in RUM of CFRP. However, there are no reports on power consumption in RUM of CFRP. This paper reports the first study on power consumption in RUM of CFRP. It reports an experimental investigation on effects of input variables (ultrasonic power, tool rotation speed, feedrate, and type of CFRP) on power consumption of each component (including ultrasonic power supply, spindle motor, coolant pump, and air compressor) and the entire RUM system.

Ultrasonic vibration-assisted pelleting of wheat straw: A predictive model for energy consumption using response surface methodology

“…This trend could be explained as that since ultrasonic power was proportional to the vibration amplitude of the tool, as ultrasonic power increased, more energy would be consumed to generate higher vibration amplitude of the tool. The same trend was also observed on a rotary ultrasonic machine (Model Series 10, SonicMill, Albuquerque, NM, USA) containing the same power supply and made by the same manufacturer as the unit used in this work [34]. A different trend was reported by Zhang et al [30], who studied effects of ultrasonic power on energy consumption in UV-A pelleting of wheat straw, sorghum stalk, big bluestem, and corn stover.…”

Rotary ultrasonic elliptical machining for side milling of CFRP: Tool performance and surface integrity

“…Another typical application of this tool (in the shape of a hollow cylinder, named diamond core drill) consists in grinding holes on CFRP components in rotary ultrasonic elliptical machining (RUEM) and rotary ultrasonic machining (RUM). Excellent chip removal conditions and the high machined surface quality were achieved in both of the processes [15][16][17][18]. Thus, ultrasonic vibration assisted milling with diamond grinding tool may provide a satisfactory approach to overcome the associated problems in conventional grinding of CFRP.…”

Experimental investigations on core drilling by ultrasonic-vibration-assisted grinding for hard-to-machine materials - a review

“…Seven brittle materials (Al 2 O 3 , ZrO 2 / Al 2 O 3 , dental ceramics, SiC, poly-crystalline, CMC, and silicon), two ductile materials (Ti and stainless steel) and two carbon fibre composites (C/C, CFRP) were studied. Seven of the 13 input variables were studied for ductile materials, six of them for brittle materials and only two of them for carbon fibre composites (Cong et al, 2011(Cong et al, , 2013a(Cong et al, , 2012a(Cong et al, , 2012b(Cong et al, , 2012c2012d;Ma, 2013). There is a phenomena that cutting force in UVAG was lower than that in traditional diamond grinding.…”