Ultrasonic vibration-assisted machining: principle, design and application

Xu, Weixing; Zhang, Liangchi

doi:10.1007/s40436-015-0115-4

Cited by 140 publications

(47 citation statements)

References 130 publications

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“…According to Eqs. (13)(14)(15)(16)(17)(18)(19)(20)(21)(22)(23), the value of contact angle increases and the surface wettability turns to be more hydrophobic. In addition, it is reported that the contact angle is one of the important factors 16 indicating the surface free energy, where smaller surface free energy corresponds to higher contact angles [8].…”

Section: Wettability Testing Resultsmentioning

confidence: 99%

“…As a new machining method, vibration assisted micro milling (VAMM), featuring a periodic separation between the workpiece and the tool, offers numerous advantages such as lower cutting force, longer tool life, better surface quality, and higher machining accuracy [16][17][18][19][20][21]. VAMM has found applications in processing hard and brittle materials such as silicon, titanium alloy and ceramics [22]. Moreover, with an appropriate selection of parameters, unique surface textures can be created by VAMM.…”

Section: Introductionmentioning

confidence: 99%

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Modulation of surface wettability by vibration assisted milling

Zheng

Chen

Pozzi

et al. 2019

Precision Engineering

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Surface textures have significant influence on surface wettability. In this paper, a range of fish scales surface textures are produced by using vibration assisted micro milling.The generation principle of the surface textures and their influence on surface wettability are mathematically studied. A new contact model, which considers both liquid infiltration effects and air trapped in the microstructure, is proposed for predicting the wettability of the fish scales surface texture. Machining and hydrophobicity experiments are conducted to validate the model and results indicate that the solid surface hydrophilicity is improved by the fish scales surface textures. Moreover, under the experimental conditions used in this research, the contact angle can be controlled from 30° to 57° by adjusting the parameters that determine the fish scales. The paper concludes that vibration assisted micro milling is an effective method to modify and control surface wettability.

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Section: Wettability Testing Resultsmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Modulation of surface wettability by vibration assisted milling

Zheng

Chen

Pozzi

et al. 2019

Precision Engineering

View full text Add to dashboard Cite

show abstract

“…ductility, high tensile strength, micro-hardness, grain orientation, etc.) may change the overall machinability [20]. The current study presents an approach of applying ultrasonic vibration during the turning of Al alloys, thus, generating the UAT process.…”

Section: Experimental Descriptionmentioning

confidence: 99%

Ultrasonic Assisted Turning of Al alloys: Influence of Material Processing to Improve Surface Roughness

2019

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Ultrasonic machining has been used over a decade to enhance the surface finishing and overall processing characteristics of conventional technologies. The benefits that are usually associated to this approach generate an increasing interest in both academic and industrial fields, especially in the turning operation due to its simple application. In this study, ultrasonic assisted turning is used to study the effect of intermittent tool contact on the surface quality of cast and wrought aluminium alloys. The resulting surface roughness and topography plots were evaluated through a three-dimensional (3D) optical profilometer. Additionally, stereo microscopy and detailed by scanning electron microscopy analyzed chip shape and morphology. The experimental results show that the appropriate use of an ultrasonic intermittent tool can improve the superficial quality up to 82% and reduce the maximum peak height by 59 % for a 0.045 mm/rev feed rate. When the feed rate is increased to 0.18 mm/rev, the surface roughness may be enhanced by 60% and the maximum peak height reduced by 76%. Furthermore, due to the introduction of a distinct cutting mechanism, the traditional chip shape is modified when the ultrasonic tool excitation is applied. A model is suggested to explain the chip growth and the fracture behaviour.

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“…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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Ultrasonic vibration-assisted machining: principle, design and application

Cited by 140 publications

References 130 publications

Modulation of surface wettability by vibration assisted milling

Modulation of surface wettability by vibration assisted milling

Ultrasonic Assisted Turning of Al alloys: Influence of Material Processing to Improve Surface Roughness

Force Prediction in Ultrasonic Vibration-Assisted Milling

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