Rotary ultrasonic machining of CFRP using cold air as coolant: feasible regions

Cong, Weilong; Pei, Zhijian; Deines, Timothy W.; Treadwell, C.

doi:10.1177/0731684411416266

Cited by 47 publications

(26 citation statements)

References 24 publications

Supporting

Mentioning

Contrasting

Unclassified

Order By: Relevance

“…In order to reduce the hole surface roughness, it is important to have an efficient way to flush the swarf away. RUM employs liquid coolant or compressed air to flush the swarf in between the tool and workpiece away [17]. Intermittent rotary ultrasonic machining (intermittent RUM) is a newly introduced machining process.…”

Section: Rotary Ultrasonic Machining and Its Application To K9 Glass mentioning

confidence: 99%

Intermittent and Continuous Rotary Ultrasonic Machining of K9 Glass: An Experimental Investigation

Fernando

Zhang

Pei

et al. 2017

JMMP

View full text Add to dashboard Cite

Abstract:Rotary ultrasonic machining (RUM) is a nontraditional and cost-effective machining method for hard and brittle materials, such as ceramics, optical glass, composite materials, and so on. RUM is a hybrid process that combines the material removal mechanisms of diamond abrasive grinding and ultrasonic machining. In RUM, a rotating cutting tool with metal-bonded diamond abrasive particles is ultrasonically vibrated in the axial direction while the tool spindle is fed toward the workpiece at a constant feedrate to remove material. It has been reported that continuous rotary ultrasonic machining has been successfully used to drill holes in K9 glass. Intermittent rotary ultrasonic machining is a newly introduced ultrasonic machining process, which uses a slotted cutting tool instead of a common metal bonded diamond cutting tool as used in continuous rotary ultrasonic machining. There has been no reported study to compare the effects of intermittent RUM and continuous RUM when machining K9 glass. This paper, for the first time, presents an experimental investigation to compare intermittent RUM and continuous RUM when machining K9 glass from the perspectives of cutting force, surface roughness, and chipping size.

show abstract

Section: Rotary Ultrasonic Machining and Its Application To K9 Glass mentioning

confidence: 99%

Intermittent and Continuous Rotary Ultrasonic Machining of K9 Glass: An Experimental Investigation

Fernando

Zhang

Pei

et al. 2017

JMMP

View full text Add to dashboard Cite

show abstract

“…Also, to reduce the costs associated with cutting fluids, RUM of CFRP using cold air as coolant has been studied [Cong et al 2011abc]. Feasible regions in RUM of CFRP using cold air as coolant have been identified [Cong et al 2011b]. A comparison of RUM of CFRP using cold air and cutting fluid has been made [Cong et al 2011c].…”

Section: Introductionmentioning

confidence: 99%

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

et al. 2012

Self Cite

View full text Add to dashboard Cite

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.

show abstract

“…Xia conducted comprehensive experimental researches on drilling CFRP composites under the cryogenic condition, in which case the surface quality had positive changes. Meanwhile, chilled air was introduced into machining of CFRP, and significant reductions of tool wear and overheating damage as well as improvements of surface quality were achieved . Moreover, cryogenic CO 2 cooling, as a novel cooling method, was investigated by Nelson W. Sorbo in machining CFRP and CFRP/metal stack, and encouraging machining quality and efficiency were obtained.…”

Section: Introductionmentioning

confidence: 99%

Temperature effects in end milling carbon fiber reinforced polymer composites

Zhang

Wang

et al. 2016

Polymer Composites

View full text Add to dashboard Cite

The temperatures at the cutting area rise excessively in machining of CFRP due to the low thermal conductivity of the material. And machining damages become aggravated with cutting-area temperatures approaching to the glass transition temperature of resin matrix. Therefore, controlling the cutting-area temperature at the suitable range is remarkably important for improving machining qualities. This article presented experimental investigations into cutting-area temperature influences on cutting force, surface integrity, as well as subsurface quality in end milling of multi-directional CFRP composites, and further discussed cutting mechanism variations. The cutting-area temperatures were controlled under three ranges by employing pressured cryogenic nitrogen gas and no coolants. The machining quality under low temperature in general was better than that under high temperature. Particularly, morphologies under high temperatures indicated fibers were bended to fracture resulting in severe subsurface damages. In contrast, the hardened matrix at low temperatures offered fibers better support, and the composites were easily squeezed to rupture which led to superior cutting performance. However, as the temperature reached extremely low, the cutting force increased dramatically and then could reduce tool life. Thus the suitable temperature range is proposed for the first time in machining CFRP. POLYM. COMPOS., 00:000-000,

show abstract

Rotary ultrasonic machining of CFRP using cold air as coolant: feasible regions

Cited by 47 publications

References 24 publications

Intermittent and Continuous Rotary Ultrasonic Machining of K9 Glass: An Experimental Investigation

Intermittent and Continuous Rotary Ultrasonic Machining of K9 Glass: An Experimental Investigation

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

Temperature effects in end milling carbon fiber reinforced polymer composites

Contact Info

Product

Resources

About