Rotary ultrasonic machining of potassium dihydrogen phosphate (KDP) crystal: An experimental investigation on surface roughness

Wang, Qiangguo; Cong, Weilong; Pei, Zhijian; Gao, Hang; Kang, Renke

doi:10.1016/j.jmapro.2009.09.001

Cited by 65 publications

(33 citation statements)

References 38 publications

(28 reference statements)

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“…For coolant type, Ra was lower using cutting fluid than using cold air (Cong et al, 2011). Ra was always proportional to diamond grain diameter and inversely proportional to rotational speed except for UVAG of dental ceramics and KDP (Wang et al, 2009). In UVAG of dental ceramics, Ra decreased first and then increased as rotational speed increased, while in UVAG of KDP, a reverse trend was obtained.…”

Section: Experimental Investigations On Surface Roughnessmentioning

confidence: 93%

“…In UVAG of dental ceramics, Ra decreased first and then increased as rotational speed increased, while in UVAG of KDP, a reverse trend was obtained. Note that, the rotational speed ranged from 1,000 rpm to 4,000 rpm in UVAG of Al 2 O 3 (Zeng et al, 2008), from 2,000 rpm to 5,000 rpm in UVAG of dental ceramics (Churi et al, 2009) and from 2,000 to 6,000 rpm in UVAG of KDP (Wang et al, 2009). The inconsistent results might be due to different materials and different choices of variable range, but no explanations have been provided in the literature.…”

Section: Experimental Investigations On Surface Roughnessmentioning

confidence: 98%

See 1 more Smart Citation

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

Qin

Lei

Pei

2016

IJMR

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Ultrasonic-vibration-assisted grinding (UVAG), a hybrid machining process combining material removal mechanisms of diamond grinding and ultrasonic machining, has been used to machine various hard-to-machine materials. Large amount of research work on UVAG has been carried out since it is invented. However there are few review papers to cover the current literature on UVAG. The emphasis of this literature review is the experimental investigations of the drilling process with ultrasonic vibration using a core drill with metal-bonded diamond abrasives. Experimental results are summarised and compared. The inconsistent results and their reasons are discussed. Furthermore, directions of future research on UVAG are also presented.

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Section: Experimental Investigations On Surface Roughnessmentioning

confidence: 93%

Section: Experimental Investigations On Surface Roughnessmentioning

confidence: 98%

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

Qin

Lei

Pei

2016

IJMR

Self Cite

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“…The main purpose of the study was to make use of rotary ultrasonically assisted machining (RUM) on brittle material, investigate the application of milling on brittle materials and innovative manufacturing methods such as automated rotary ultrasonic machining. In addition, RUM is used for other brittle materials such as glass [8], potassium dihydrogen phosphate (KDP) [9], composite materials [10,11], ceramics [12], and sapphire [13].…”

Section: Introductionmentioning

confidence: 99%

The Machining of Hard Mold Steel by Ultrasonic Assisted End Milling

Tsai

Chang

2016

Applied Sciences

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Abstract:This study describes the use of ultrasonic-assisted end milling to improve the quality of the machined surface of hard Stavax (modified AISI 420) mold steel and to reduce the amount of work involved in the final polishing process. The effects of input voltage, the stretch length and cutter holding force on the amplitude of the ultrasonic vibration used were measured. The effect of ultrasonic frequency (25 and 50 kHz) and amplitude (0, 2.20 and 3.68 µm) as well as the effect of the rake angle (6 • and −6 • ) and the cutter helix angle (25 • , 35 • and 45 • ) on tool wear and quality of the workpiece surface finish were also investigated. It was found that the ultrasonic amplitude increased with cutter stretch length and input voltage, as expected. The amplitude remained constant when the cutter holding force exceeded 15 N. The experimental results showed that the ultrasonic amplitude had an optimum value with respect to surface finish. However, large amplitude ultrasonics did not necessarily improve quality. Furthermore, the cutters used for ultrasonic-assisted milling show less wear than those used for normal milling. It was also found that a positive rake angle and cutters with a large helix angle gave a better surface finish.

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“…Feng et al [12] established the theoretical model for the rotary ultrasonic face milling with the assumption that the diamond grit was spherical while the shape of the grit found was regular octahedron. Wang et al [13] conducted a study of rotary ultrasonic drilling on potassium dihydrogen phosphate (KDP) crystal and analyzed the effects of five different cutting parameters on the surface quality. The experiments were carried out; however, the model of the surface roughness was not established.…”

Section: Introductionmentioning

confidence: 99%

“…In previous study and literature review [1][2][3][4][5][6][7][8][9][10][11][12][13][14][15][16][17], it is found that there was main focus on machining ceramics and its related composite materials. The research work on rotary ultrasonic drilling of CFRP materials is rare especially on CFRP-T700.…”

Section: Introductionmentioning

confidence: 99%

Development of a cutting force prediction model based on brittle fracture for carbon fiber reinforced polymers for rotary ultrasonic drilling

Yuan

Zhang

Amin

et al. 2015

Int J Adv Manuf Technol

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Carbon fiber reinforced polymers (CFRP) T700 have got increasing demand in the aerospace industry due to their high specific strength, specific stiffness, and other unique properties. Due to their inhomogeneous, anisotropic, and thermal properties, it is challenging to achieve desired accuracy and to avoid from delamination, chip-off, cracking, and burning especially in the drilling process. The cutting force is the critical parameter which is required to minimize in order to drill a hole with better accuracy and minimize defects. In this research, the brittle fracture approach was adopted and a cutting force model was developed for CFRP-T700 based on the rotary ultrasonic drilling (RUD) process. The experimental RUD was carried out on CFRP-T700 material and found that the feed rate and spindle speed are two main parameters that affect the cutting force in RUD. The cutting force data obtained from the model and experimental setup were then analyzed and found that there is small variation even below 10 % (max value of variation is 8.5 % and the average value is 0.49 %) between simulated and measured values. So, the developed cutting force model was validated and found robust. Also, it was found that with four times increase of feed rate, there is also an increase of material removal rate (MRR) four times with the decrease in the cutting force. Moreover, this model will be much helpful to keep cutting force within limits through the optimal set of parameters as feed rate and spindle speed without extensive experimentation of such costly materials.

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Rotary ultrasonic machining of potassium dihydrogen phosphate (KDP) crystal: An experimental investigation on surface roughness

Cited by 65 publications

References 38 publications

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

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

The Machining of Hard Mold Steel by Ultrasonic Assisted End Milling

Development of a cutting force prediction model based on brittle fracture for carbon fiber reinforced polymers for rotary ultrasonic drilling

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