Surface formation modeling and surface integrity research of normal ultrasonic assisted flexible abrasive belt grinding

Li, Shaochuan; Xiao, Guijian; Chen, Benqiang; Zhuo, Xiaoqin; Xu, J. Q.; Huang, Yun

doi:10.1016/j.jmapro.2022.05.045

Cited by 21 publications

(4 citation statements)

References 21 publications

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“…Several studies have confirmed the benefits of utilizing ultrasonic-assisted grinding tools to achieve high-quality material removal across various machining and vibration parameters [86]. Li et al [87] combined vibration-assisted machining technology with abrasive belt grinding, as shown in figure 8. They experimentally analyzed the impact of linear speed and feed rate on the machined surface and simulated the material removal mode of sand belts with flexible characteristics under vibration assistance.…”

Section: Tool Ultrasonic Vibration-assisted Grindingmentioning

confidence: 94%

Nontraditional energy-assisted mechanical machining of difficult-to-cut materials and components in aerospace community: a comparative analysis

Zhao,

Ding

et al. 2024

Int. J. Extrem. Manuf.

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Difficult-to-cut materials such as titanium alloys, high-temperature alloys, metal/ceramic/polymer-matrix composites, hard and brittle materials, as well as geometrically complex components such as thin-walled structures, micro channels and complex surfaces, are widely used in aerospace community. Mechanical machining is the main material removal process and responsible for the vast majority of material removal for aerospace components. Nevertheless, it encounters many problems in terms of severe and rapid tool wear, low machining efficiency, and deteriorated surface integrity. Nontraditional energy-assisted mechanical machining is a hybrid process in which nontraditional energies, e.g., vibration, laser, electric, etc., are applied to improve the machinability of local material and decrease burden of mechanical machining. It provides a feasible and promising way for improving machinability and surface quality, reducing process forces, and prolonging tool life, etc. However, systematic reviews of this technology are lacking with respect to the current research status and development direction. This paper reviews recent progress in nontraditional energy-assisted mechanical machining of difficult-to-cut materials and components in aerospace community. It focuses on the processing principles, material responses under nontraditional energy, resultant forces and temperatures, material removal mechanisms and applications of these processes including vibration-, laser-, electric-, magnetic-, chemical-, cryogenic cooling-, and hybrid nontraditional energies-assisted mechanical machining. Eventually, a comprehensive summary of the principles, advantages and limitations for each hybrid process is provided, and future perspectives on forward design, device development and sustainability of nontraditional energy-assisted mechanical machining processes are discussed.

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Section: Tool Ultrasonic Vibration-assisted Grindingmentioning

confidence: 94%

Nontraditional energy-assisted mechanical machining of difficult-to-cut materials and components in aerospace community: a comparative analysis

Zhao,

Ding

et al. 2024

Int. J. Extrem. Manuf.

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“…The distribution of elements in a material affects its mechanical properties and, thus, its service performance after forming (Xie et al, 2017;Li S. C. et al, 2022;Li Z. F. et al, 2022). In order to explore the cause of the crack source, it is necessary to explore the distribution difference of elements and morphological characteristics near the 3, respectively.…”

Section: Fatigue Section Characteristicsmentioning

confidence: 99%

Fatigue failure mechanism analysis of 1Cr17Ni2 stainless steel blades ground by an abrasive belt

Zhang¹,

Li²,

Wang

et al. 2023

Front. Mater.

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Fatigue failure, as the main failure form of aero-engine blades, has a direct impact on the reliability and service life of aviation equipment. In order to improve the service performance of machined blades, it is necessary to understand the failure process and failure mechanism of blades and then optimize the grinding process. This paper takes abrasive belt grinding of an 1Cr17Ni2 stainless steel blade as the research object and analyzes the fatigue failure mechanism by characterizing the surface morphology, cross-sectional microstructure, and cross-sectional characteristics of the fatigue failure blade. The results show that cracks are prone to propagate in carbon-rich areas with poor mechanical properties inside the material, and the accumulation of large-size carbon-rich areas leads to continuous cracks easily and accelerates crack growth. The grinding process promotes the migration and consumption of surface carbon elements and forms a carbon consumption layer on the surface of the material, which can inhibit the initiation of fatigue cracks. The point-like pits on the ground surface have an adverse effect on the fatigue life and play a role in the initiation of fatigue crack enhancement. The direction of material research and development to homogenize the structure of the material and the direction of anti-fatigue grinding to increase the thickness of the carbon consumption layer on the ground surface and avoid the damage of micro-pits are proposed. The research has important guiding significance for anti-fatigue machining of key components.

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“…MR finishing, which uses the MR effect to form a "flexible polishing brush" on the surface of the polishing tool, is a typical flexible finishing technology 14 – 16 . It overcomes the shortcomings of easy pollution, low efficiency and low controllability of traditional electrochemical polishing 17 , 18 , magnetic abrasive finishing 19 , 20 , ultrasonic polishing technology 21 , 22 , and has advantages of high surface quality, low surface damage, high efficiency, low energy consumption, controllable material removal rate, etc. 23 – 25 .…”

Section: Introductionmentioning

confidence: 99%

Improvement of roughness in ultrasonic assisted magnetorheological finishing of small titanium alloy nuts by orthogonal test method

Bi,

Ji,

Wang

et al. 2024

Sci Rep

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Titanium alloy with high corrosion resistance, high strength-to-density ratio, and excellent biocompatibility has a wide range of applications in the field of biomedical implants. Polishing experiments of titanium alloy with a small size and complex shapes were investigated using an ultrasonic assisted magnetorheological finishing (UMRF) device excited by a three-pole magnetic field generator. The models of the normal force and the shear force were first proposed based on the Preston equation to analyze the mechanism of material removal in the UMRF process. Subsequently, the single-factor experiments using titanium alloy nuts (M3) and the MR polishing fluid with silicon carbide abrasives were carried out. Furthermore, to improve the surface roughness and the change rate of surface roughness of nuts, orthogonal tests with a standard L9(34) orthogonal array were designed and performed based on the optimized process parameters obtained from the single-factor experiment. The results indicated the effect on surface roughness and change rate of surface roughness as applied current > roller speed > ultrasonic amplitude > spindle speed and applied current > roller speed > spindle speed > ultrasonic amplitude, respectively. Moreover, the surface roughness was improved from an initial 1.247 μm to a final 0.104 μm after the polishing for 80 min under these optimal process parameters.

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Surface formation modeling and surface integrity research of normal ultrasonic assisted flexible abrasive belt grinding

Cited by 21 publications

References 21 publications

Nontraditional energy-assisted mechanical machining of difficult-to-cut materials and components in aerospace community: a comparative analysis

Nontraditional energy-assisted mechanical machining of difficult-to-cut materials and components in aerospace community: a comparative analysis

Fatigue failure mechanism analysis of 1Cr17Ni2 stainless steel blades ground by an abrasive belt

Improvement of roughness in ultrasonic assisted magnetorheological finishing of small titanium alloy nuts by orthogonal test method

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