State-of-the-art review on vibration-assisted milling: principle, system design, and application

Chen, Wanqun; Huo, Dehong; Shi, Yilun; Hale, J. M.

doi:10.1007/s00170-018-2073-z

Cited by 60 publications

(23 citation statements)

References 77 publications

(94 reference statements)

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“…However, according to the crest from the surface, it has been removed through introducing vibration-assisted by the alternating cycle phenomenon [18]. Thus, it is assumed that a high-quality surface can be achieved by the vibratory workpiece.…”

Section: Design Of Proposed 3-dof Rotary Vibration-assisted Micropmentioning

confidence: 99%

Development of a Novel Three Degrees-of-Freedom Rotary Vibration-Assisted Micropolishing System Based on Piezoelectric Actuation

Yan

Chen

et al. 2019

Micromachines

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The limited degrees of freedom (DOF) and movement form of the compliant vibration-assisted processing device are inherent constraints of the polishing technique. In this paper, a concept of a 3-DOF rotary vibration-assisted micropolishing system (3D RVMS) is proposed and demonstrated. The 3-DOF means the proposed vibration-assisted polishing device (VPD) is driven by three piezo-electric (PZT) actuators. Compared with the current vibration-assisted polishing technology which generates a trajectory with orthogonal actuators or parallel actuators, a novel 3-DOF piezoelectrically actuated VPD was designed to enable the workpiece to move along the rotational direction. Meanwhile, the proposed VPD can deliver large processing stoke in mrad scale and can be operated at a flexible non-resonant mode. A matrix-based compliance modeling method was adopted for calculating the compliance and amplification ratio of the VPD. Additionally, the dynamic and static properties of the developed VPD were verified using finite element analysis. Then, the VPD was manufactured and experimentally tested to investigate its practical performance. Finally, various polished surfaces which used silicon carbide (SiC) ceramic as workpiece material were uniformly generated by the high-performance 3D RVMS. Compared with a nonvibration polishing system, surface roughness was clearly improved by introducing rotary vibration-assisted processing. Both the analysis and experiments verified the effectiveness of the present 3D RVMS for micro-machining surfaces.

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Section: Design Of Proposed 3-dof Rotary Vibration-assisted Micropmentioning

confidence: 99%

Development of a Novel Three Degrees-of-Freedom Rotary Vibration-Assisted Micropolishing System Based on Piezoelectric Actuation

Yan

Chen

et al. 2019

Micromachines

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“…The first two types are described by equations (1)- (8). Type I criterion is satisfied when the cutting direction component of the relative velocity between tool and workpiece is opposite to the tool rotation direction [1,23]. As shown in Fig.…”

Section: Force Predictive Model In Ultrasonic Vibration-assisted Millmentioning

confidence: 99%

“…Micro-scale high frequency vibration with small amplitude is applied on the tool or workpiece to realize the tool-workpiece separation during the milling process. Several research studies have concluded that the tool-workpiece separation in ultrasonic vibration-assisted milling is the main reason for several benefits including improved surface quality [1], lower machining forces, and extended tool life [2]. This tool-workpiece interaction is microscopically non-monotonic which facilitates chip separation and therefore reduces machining forces.…”

Section: Introductionmentioning

confidence: 99%

Force Prediction in Ultrasonic Vibration-Assisted Milling

Feng

Hsu

et al. 2019

Preprint

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Force reduction is one of the most important benefit of applying ultrasonic vibration on milling. However, most of studies so far are limited to experimental investigation. In the current study, an analytical predictive model on cutting forces in ultrasonic vibration-assisted milling is proposed. The three types of tool-workpiece criteria are considered based on the instantaneous position and velocity of tool center. Type I criterion indicates that there is no contact if the instantaneous velocity is opposite to tool rotation direction. Type II criterion checks whether the vibration displacement is larger than the instantaneous uncut chip thickness. Type III criterion considers the overlaps between current and previous tool paths due to vibration. If none of these criteria is satisfied, milling forces are nonzero. Then the calculation is performed by transforming milling and tool geometry configuration to orthogonal cutting at each instant. The orthogonal cutting forces are predicted through the exhaustive search of shear angle and calculation of shear flow stress on tool-chip interface. The axial force is then calculated based on tool geometry, and the milling forces in feed, cutting, and axial directions are calculated after coordinate transformation. The proposed predictive force model in ultrasonic vibration-assisted milling is validated through comparison to experimental measurements on Aluminum alloy 2A12. The predicted values are able to match the measured milling forces with high accuracy of average difference of 13.6% in feed direction and 13.8% in cutting direction.

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“…VAM has been applied to various machining processes, including turning, drilling, grinding, and more recently milling, for the processing of hard-to-. [1], [2] machine materials LITERATURE SURVEY [3] Naresh Kumar Maroju, Krishna P. Vamsi & Jin Xiaoliang, 2017 has studied the mechanics of orthogonal turning with lowfrequency (less than 1000 Hz) vibration assistance. Finite element simulations are conducted to predict and compare the stresses, forces, and temperature between conventional turning (CT) and low frequency vibration-assisted turning (LVAT).…”

Section: Introductionmentioning

confidence: 99%

Low Frequency Vibration Turning And Its Development: A Review

Kamble¹,

Deshpande²

2019

PIJR

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Low frequency vibration Turning is a peripheral energy assisted machining method to improve the material removal process by superimposing high frequency and small amplitude vibration on either tool or work piece motion.The servo axes vibrated in the axial direction and cutting is achieved while synchronizing this vibration with the rotation of the spindle.Because “air-cutting”time is provided along with cutting,it is characterized by intermittent removal of chips.It is ideal for cutting difficult-to-cut materials like Inconel, stainless steel and copper. It is state-of-the-art and overwhelms various risks associated with these materials, such as entanglement of chips and built-up edges.Three main problems, lack of awareness of mechanism,establishment of a standard for the choice of certain parameters,application level,still in expertise for low-frequency vibration cutting were explored and the development tendency as well as the prospect of low-frequency vibration turning in future was foreseen.

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State-of-the-art review on vibration-assisted milling: principle, system design, and application

Cited by 60 publications

References 77 publications

Development of a Novel Three Degrees-of-Freedom Rotary Vibration-Assisted Micropolishing System Based on Piezoelectric Actuation

Development of a Novel Three Degrees-of-Freedom Rotary Vibration-Assisted Micropolishing System Based on Piezoelectric Actuation

Force Prediction in Ultrasonic Vibration-Assisted Milling

Low Frequency Vibration Turning And Its Development: A Review

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