Study on predictive model of cutting force and geometry parameters for oblique elliptical vibration cutting

Lin, Jieqiong; Han, Jiang; Zhou, Xiaoqin; Hao, Zhaopeng; Lu, Mingming

doi:10.1016/j.ijmecsci.2016.08.004

Cited by 46 publications

(13 citation statements)

References 17 publications

Supporting

Mentioning

Contrasting

Unclassified

Order By: Relevance

“…In the 2D-VAC process, it has been thought that there are three main mechanisms [24,32,33] during cutting in one single cycle of cut. The first is the traditional cutting mechanism (TC-like), the second is the static-friction mechanism, and the third is the reverse-kinetic mechanism, as shown in Fig.…”

Section: Fig 1 Illustration Of 2d-vac With Merchant's Circle Reverse-kineticsmentioning

confidence: 99%

Analytical, FEA, and experimental research of 2D-Vibration Assisted Cutting (2D-VAC) in titanium alloy Ti6Al4V

Kurniawan

Ahmed

Ali

et al. 2021

Int J Adv Manuf Technol

View full text Add to dashboard Cite

In the 2D-Vibration Assisted Cutting (2D-VAC) method, the cutting tool shakes in a 2-dimensional approach because of superimposed high-frequency modulation. This high-frequency modulation effect creates a displacement at a tiny scale of micrometers and causes an escalation in the resultant cutting speed. Consequently, 2D-VAC has superior advantages compared to traditional cutting (TC). This manuscript describes research on 2D-VAC that focuses on modeling cutting forces (mathematical model) and finite element analysis (FEA) results. The FEA results are focused on the von Mises stress, plastic strain, cutting force, cutting temperature, and residual stress. In addition, an experiment for the chip formation, microstructure layer, and micro-hardness was also analyzed in this study. According to the modeling results, the cutting force has a comparable pattern to the FEA results. The stress contour result confirms that the 2D-VAC method has lower stress than that in the TC method during tool retraction mode. Additionally, the plastic strain in the 2D-VAC method can be higher than that in the TC method. According to the temperature results, the peak temperature in the 2D-VAC could be higher than that in the TC method. The residual stress shows that there is a compressive effect. Thus, the compressive stress is higher than that in the TC method. Micro-hardness results confirmed that there is not too much change from the original surface in the 2D-VAC method. The result of micro-structure morphology also confirmed that there is a significant shear deformation flow in case of the TC method, although less occurs in the 2D-VAC method.

show abstract

Section: Fig 1 Illustration Of 2d-vac With Merchant's Circle Reverse-kineticsmentioning

confidence: 99%

Analytical, FEA, and experimental research of 2D-Vibration Assisted Cutting (2D-VAC) in titanium alloy Ti6Al4V

Kurniawan

Ahmed

Ali

et al. 2021

Int J Adv Manuf Technol

View full text Add to dashboard Cite

show abstract

“…𝑦 𝑒 (𝑡 𝑇 )−𝑦 𝑒 (𝑡 𝑃 ) = tan(𝛼 𝑜 ) In the 2D-VAC process, it has been thought that there are three main mechanisms [24,32,33] during cutting in one single cycle of cut. The first is the traditional cutting mechanism (TC-like), the second is the static-friction mechanism, and the third is the reverse-kinetic mechanism, as shown in Fig.…”

Section: Fig 1 Illustration Of 2d-vac With Merchant's Circle Reverse-kineticsmentioning

confidence: 99%

Analytical, FEA, And Experimental Research of 2D-Vibration Assisted Cutting ( 2D-VAC) In Titanium Alloy Ti6Al4V

Kurniawan

Ahmed

Park

et al. 2021

Preprint

View full text Add to dashboard Cite

In the 2D-Vibration Assisted Cutting (2D-VAC) method, the cutting tool shakes in a 2-dimensional approach because of superimposed high-frequency modulation. This high-frequency modulation effect creates a displacement at a tiny scale of micrometers and causes an escalation in the resultant cutting speed. Consequently, 2D-VAC has superior advantages compared to traditional cutting (TC). This manuscript describes research on 2D-VAC that focuses on modeling cutting forces (mathematical model) and finite element analysis (FEA) results. The FEA results are focused on the von Mises stress, plastic strain, cutting force, cutting temperature, and residual stress. In addition, an experiment for the chip formation, micro-structure layer, and micro-hardness was also analyzed in this study. According to the modeling results, the cutting force has a comparable pattern to the FEA results. The stress contour result confirms that the 2D-VAC method has lower stress than that in the TC method during tool retraction mode. Additionally, the plastic strain in the 2D-VAC method can be higher than that in the TC method. According to the temperature results, the peak temperature in the 2D-VAC could be higher than that in the TC method. The residual stress shows that there is a compressive effect. Thus, the compressive stress is higher than that in the TC method. Micro-hardness results confirmed that there is not too much change from the original surface in the 2D-VAC method. The result of micro-structure morphology also confirmed that there is a significant shear deformation flow in case of the TC method, although less occurs in the 2D-VAC method.

show abstract

“…Compared with conventional diamond cutting, the intermittent tool/workpiece contact endows the elliptical vibration-assisted diamond cutting technique with not only a surface-texturing ability but also chipbreaking [22] and burr-suppression [23] features. It can, therefore, obtain both precision and ultra-precision parts with high efficiency and low environmental impact [24]. In this approach, the attainable wavelengths and heights of periodical microstructures are determined by the operational frequencies and input voltages for the EVC device.…”

Section: Introductionmentioning

confidence: 99%

A high-frequency non-resonant elliptical vibration-assisted cutting device for diamond turning microstructured surfaces

Wang

Luo

Liu

et al. 2021

Int J Adv Manuf Technol

View full text Add to dashboard Cite

In recent years, research has begun to focus on the development of non-resonant elliptical vibration-assisted cutting (EVC) devices, because this technique offers good flexibility in manufacturing a wide range of periodic microstructures with different wavelengths and heights. However, existing non-resonant EVC devices for diamond turning can only operate at relatively low frequencies, which limits their machining efficiencies and attainable microstructures. This paper concerns the design and performance analysis of a non-resonant EVC device to overcome the challenge of low operational frequency. The structural design of the non-resonant EVC device was proposed, adopting the leaf spring flexure hinge (LSFH) and notch hinge prismatic joint (NHPJ) to mitigate the cross-axis coupling of the reciprocating displacements of the diamond tool and to combine them into an elliptical trajectory. Finite element analysis (FEA) using the mapped meshing method was performed to assist the determination of the key dimensional parameters of the flexure hinges in achieving high operational frequency while considering the cross-axis coupling and modal characteristics. The impact of the thickness of the LSFH on the sequence of the vibrational mode shape for the non-resonant EVC device was also quantitatively revealed in this study. Moreover, a reduction in the thickness of the LSFH can reduce the natural frequency of the non-resonant EVC device, thereby influencing the upper limit of its operational frequency. It was also found that a decrease in the neck thickness of the NHPJ can reduce the coupling ratio. Experimental tests were conducted to systematically evaluate the heat generation, cross-axis coupling, modal characteristics and diamond tool’s elliptical trajectory of a prototype of the designed device. The test results showed that it could operate at a high frequency of up to 5 kHz. The cross-axis coupling ratio and heat generation of the prototype are both at an acceptable level. The machining flexibility and accuracy of the device in generating microstructures of different wavelengths and heights through tuning operational frequency and input voltage have also been demonstrated via manufacturing the micro-dimple arrays and two-tier microstructured surfaces. High-precision microstructures were obtained with 1.26% and 10.67% machining errors in wavelength and height, respectively.

show abstract

Study on predictive model of cutting force and geometry parameters for oblique elliptical vibration cutting

Cited by 46 publications

References 17 publications

Analytical, FEA, and experimental research of 2D-Vibration Assisted Cutting (2D-VAC) in titanium alloy Ti6Al4V

Analytical, FEA, and experimental research of 2D-Vibration Assisted Cutting (2D-VAC) in titanium alloy Ti6Al4V

Analytical, FEA, And Experimental Research of 2D-Vibration Assisted Cutting ( 2D-VAC) In Titanium Alloy Ti6Al4V

A high-frequency non-resonant elliptical vibration-assisted cutting device for diamond turning microstructured surfaces

Contact Info

Product

Resources

About