Understanding of Ultrasonic Assisted Machining with Diamond Grinding Tool

Park, Kyung-Hee; Hong, Yun-Hyuck; Kim, Kyeong-Tae; Lee, Seok-Woo; Choi, Hon-Zong; Choi, Young-Jae

doi:10.4236/mme.2014.41001

Cited by 13 publications

(4 citation statements)

References 11 publications

(14 reference statements)

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“…Additionally, materials with higher hardness experience a greater reduction in grinding forces, and ultrasonic vibration proves effective in minimizing occurrences of grinding burns. Park et al [7]conducted experimental research on alumina ceramics and found that ultrasonically assisted grinding, compared to conventional grinding(CG), significantly reduces grinding forces by approximately 20% to 30% and surface roughness by 5% to 15%. Moreover, surface roughness is further improved under reduced feed rates and increased grinding speeds.…”

Section: Introductionmentioning

confidence: 99%

Prediction method for residual stress evolution caused by rolling/sliding contact in ultrasonic vibration-assisted grinding

Ye,

Jun,

Tang

et al. 2024

Preprint

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Ultrasonic vibration-assisted grinding (UVAG) technology has advantages in improving part surface integrity. Currently, the calculation of residual stresses in UVAG typically relies on commercial finite element software. However, because commercial finite element software is not specialized for residual stress calculations, the computational efficiency could be higher, and the accuracy could be better. This paper proposes a semi-analytical residual stress prediction model that considers the Influence of ultrasonic vibration. This paper introduces a semi-analytical residual stress prediction model that considers the impact of ultrasonic vibration. The model calculates the grinding mechanical and thermal stress fields separately using contact mechanics and finite difference methods. Based on Hertz's contact theory and Timoshenko's thermoelastic theory, a correlation model is provided for the association between mechanical and thermal loads with the internal stresses in the workpiece. Subsequently, the residual stress field is solved by considering the thermal-mechanical coupling effects in UVAG. Ultrasonic-assisted grinding experiments were conducted using 12Cr2Ni4A alloy steel as the object, and the maximum error between the predicted residual stresses by the model and the measured residual stresses was 10.5%.In addition, the detailed discussion on the Influence of grinding parameters on residual stress reveals that reducing the grinding wheel speed can significantly increase surface compressive residual stress. The paper's research shows that the residual stress distribution obtained by the new residual stress calculation model is correct, and the calculation efficiency is high, providing a new method for predicting residual stress in UVAG.

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Section: Introductionmentioning

confidence: 99%

Prediction method for residual stress evolution caused by rolling/sliding contact in ultrasonic vibration-assisted grinding

Ye,

Jun,

Tang

et al. 2024

Preprint

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“…In contrast, these disadvantages are not the issue for Rotary Ultrasonic machining (RUM). A study discovered that the use of RUM provides a good outcome in better surface roughness and fracture strengthboth obtained by the reduction of cutting forces and tool wear [11].…”

Section: Introduction (Heading 1)mentioning

confidence: 99%

“…Recent researches on machining common material for die and mould making are mostly interested in EDM. Optimization of the EDM input parameters based on Ra as the output is the main research study conducted through statistical approaches [11,22,23,24,25,26,27] and very few were done by soft-computing [28]. The rest of the researchers' interests in this line of study was conducted through other machining such as laser milling machining [29]; hard turning machining [30]; and micro-milling [31].…”

Section: Introduction (Heading 1)mentioning

confidence: 99%

Multi-Objective Optimization of Input Machining Parameters to Machined AISI D2 Tool Steel Material

Hashim

Razak

Yusoff

2023

IJCIT

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Poor surface finish on die and mould transfers the bad quality to processed parts. High surface roughness is an example of bad surface finish that is normally reduced by manual polishing after conventional milling machining process. Therefore, in order to avoid disadvantages by manual polishing and disadvantage by the machining, a sequence of two machining operations is proposed. The main operation is run by the machining and followed by Rotary Ultrasonic Machining Assisted Milling (RUMAM). However, this sequence operation requires optimum input parameters to generate the lowest surface roughness. Hence, this paper aims to optimize the input parameters for both machining operations by three soft-computing approaches – Genetic Algorithm, Tabu Search, and Particle Swarm Optimization. The method adopted in this paper begins with a fitness function development, optimization approach usage and ends up with result evaluation and validation. The soft-computing approaches result outperforms the experiment result in having minimum surface roughness. Based on the findings, the conclusion suggests that the lower surface roughness can be obtained by applying the input parameters at maximum for the cutting speed and vibration frequency, and at minimum for machining feed rate. This finding assists manufacturers to apply proper input values to obtain parts with minimum surface roughness.

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“…Extensive experimental studies have been conducted on surface roughness in the UVAG of brittle materials, and the influences of machining variables (spindle rotational speed, feed rate, and cutting depth) on surface roughness have been revealed [ 6 , 7 , 8 ]. With the assistance of ultrasonic vibration, the surface quality is better compared to conventional grinding [ 9 ]. For dental ceramics, the machined surface roughness has a crucial effect on the service life of ceramic dentures.…”

Section: Introductionmentioning

confidence: 99%

Prediction of the Surface Roughness in Ultrasonic Vibration-Assisted Grinding of Dental Zirconia Ceramics Based on a Single-Diamond Grit Model

Xiao

2021

Micromachines

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Ultrasonic vibration-assisted grinding (UVAG) is regarded as a superior method for the fabrication of ceramic dentures, due to its outstanding performance in hard and brittle materials’ machining. The surface roughness of dentures has a critical effect on the bonding and wear performance between dentures and natural teeth. Accomplishing the prediction of surface roughness will promote the application of UVAG in dental restoration significantly. However, the investigation about surface roughness modeling in the UVAG of ceramics is limited. In this study, a comprehensive surface roughness model was proposed with the consideration of the diamond grits’ random distribution, brittle fracture removal, and ultrasonic vibration characteristics. Based on the indentation fracture removal mechanism, the material removal process was modeled. Rayleigh’s probability density function was introduced to characterize the random distribution of the grits. Besides, the ultrasonic vibration was considered via the analysis of the single-diamond grit motion. Finally, the comprehensive model was developed with the consideration of all the diamond grits. Afterward, the verification experiments were carried out. The experimental results agreed well with the model predictions. Therefore, the comprehensive model can be applied to evaluate the surface roughness and can provide an in-depth understanding of the surface formation in the UVAG of ceramics.

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Understanding of Ultrasonic Assisted Machining with Diamond Grinding Tool

Cited by 13 publications

References 11 publications

Prediction method for residual stress evolution caused by rolling/sliding contact in ultrasonic vibration-assisted grinding

Prediction method for residual stress evolution caused by rolling/sliding contact in ultrasonic vibration-assisted grinding

Multi-Objective Optimization of Input Machining Parameters to Machined AISI D2 Tool Steel Material

Prediction of the Surface Roughness in Ultrasonic Vibration-Assisted Grinding of Dental Zirconia Ceramics Based on a Single-Diamond Grit Model

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