Simulation-based design of an ultrasonic-assisted air bearing spindle for micro machining

Greco, Sebastian; Lange, Andreas; Kirsch, Benjamin; Aurich, Jan C.

doi:10.1016/j.procir.2019.04.163

Cited by 3 publications

(3 citation statements)

References 6 publications

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“…In addition, the higher compressive strength of the materials provides an opportunity to operate at a higher stress, compared to brittle piezoelectric ceramics; [ 71,72 ] for example, Terfenol‐D can exhibit a compressive strength in excess of 300 MPa. [ 73 ] Given the high stress and power intensity associated with ripple harvesting, it would be of interest to examine the potential of magnetostrictive materials in more detail. The potential disadvantages of using such materials are the need for current collection coils and bias magnets, which can increase harvester size and complexity, and the strong nonlinear properties of the materials.…”

Section: Modeling and Prototypesmentioning

confidence: 99%

Hydraulic Pressure Ripple Energy Harvesting: Structures, Materials, and Applications

Xiao

Pan

Chu

et al. 2022

Advanced Energy Materials

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The need for wireless condition monitoring and control of hydraulic systems in an autonomous and battery‐free manner is attracting increasing attention in an effort to provide improved sensing functionality, monitoring of system health, and to avoid catastrophic failures. The potential to harvest energy from hydraulic pressure ripples and noise is particularly attractive since they inherently have a high energy intensity, which is associated with the hydraulic mean pressure and flow rate. This paper presents a comprehensive overview of the state of the art in hydraulic pressure energy harvesting, which includes the fundamentals of pressure ripples in hydraulic systems, the choice of electroactive materials and device structures, and the influence of the fluid–mechanical interface. In addition, novel approaches for improving the harvested energy and potential applications for the technology are discussed, and future research directions are proposed and outlined.

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Section: Modeling and Prototypesmentioning

confidence: 99%

Hydraulic Pressure Ripple Energy Harvesting: Structures, Materials, and Applications

Xiao

Pan

Chu

et al. 2022

Advanced Energy Materials

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“…To reduce the radial vibration of the rotor, it is very important to increase the flexural stiffness of the overhang area so that the radial vibration can be completely reduced to an acceptable level for the final cutting operation. The results showed that the increase in pump pressure and reduction of the bearing distance are effective methods to reduce radial vibration Greco et al, 5 investigated the use of air bearings with ultrasonic aid for machining applications. The use of this type of spindle led to a reduction in cutting forces, tool wear, and in particular the expansion of the range of machinable materials at the micro-level.…”

Section: Introductionmentioning

confidence: 99%

Machining performance on AISI 304 steel in the milling machine with mechanical and hydraulic spindle

Shirazi

Najafabadi

Amini

2023

Proceedings of the Institution of Mechanical Engineers, Part E:

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Milling machines are widely used for producing a range of products used across various industries such as mold and dies, consumer products, automotive, etc. One of the main components of a milling machine is the spindle drive. The spindle essentially provides the rotational movement of the cutting tool and the power required for material cutting. Commonly, a servo or gearbox electric motor is used for powering the spindle. An alternative method is to use a hydraulic-powered motor. In this study, a hydraulic-powered spindle is developed and installed on a milling machine. Analysis of the milling process with the hydraulic spindle as well as the determination of machining parameters is compared with the conventional mechanical spindle. Mechanical spindles have disadvantages such as unstable spindle speeds under different operating conditions, mechanical impedance in gears, and thermal stress problems, which can have negative effects on part surface quality and cutting forces. On the other hand, the hydraulic spindle has advantages, such as higher stability, higher performance accuracy, and thermal stress removal, which may be the main factors in this study. Milling experiments were performed using AISI 304 stainless steel to compare the performance of the hydraulic spindle with the mechanical spindle in terms of surface roughness and cutting forces. Three factors including spindle rotational speed, feed rate, and depth of cut were selected as input parameters. The results showed that surface roughness and cutting force in hydraulic spindle milling improved significantly compared to that from the mechanical spindle.

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“…These slug-tracking methods do not consider the unsteady flows with slugs that occupy most of cross-sectional area of pipes. In applications to simulation-based design (Greco et al, 2019, as an example) of flow channels in chemical processing and analysis, flow in pipes should be calculated with a small number of elements to reduce calculation cost and confirm design parameters.…”

Section: Introductionmentioning

confidence: 99%

One-dimensional numerical calculation for unsteady gas-liquid flow in micro channels with air gaps

Noda

Inaba

2021

JFST

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A numerical calculation model for gas-liquid unsteady two-phase flow in a micro channel was established and validated. The model focuses on flow in a channel including air gaps. It also reduces calculation cost by minimizing the number of control-volume elements compared with conventional numerical methods for gasliquid two-phase flow. Gas-liquid two-phase flow in channels with diameters of 1 to 2 mm is important in liquid transportation in chemical processing and analysis. As for designing flow channels in chemical processing and analysis, simple numerical models are desirable to evaluate many possible patterns quickly. The model uses moving boundaries that correspond to gas-liquid interfaces, but it represents boundaries between different channels with fixed boundaries. By setting several different configurations of air gaps, the numerical model was validated in regard to position and volume of air gaps in the channel. As an application of the numerical model to the design of flow channels in chemical processing and analysis, the necessary movement conditions of a syringe pump to achieve quick liquid transportation were investigated. By applying the numerical model, the necessary conditions to minimize flow rate oscillation were determined. In simulation-based design of microchannel, the numerical model in this research is an effective tool to determine design parameters quickly.

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Simulation-based design of an ultrasonic-assisted air bearing spindle for micro machining

Cited by 3 publications

References 6 publications

Hydraulic Pressure Ripple Energy Harvesting: Structures, Materials, and Applications

Hydraulic Pressure Ripple Energy Harvesting: Structures, Materials, and Applications

Machining performance on AISI 304 steel in the milling machine with mechanical and hydraulic spindle

One-dimensional numerical calculation for unsteady gas-liquid flow in micro channels with air gaps

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