A cutting force model for rotary ultrasonic machining of brittle materials

Liu, Defu; Cong, Weilong; Pei, Zhijian; Tang, Yongjun

doi:10.1016/j.ijmachtools.2011.09.006

Cited by 189 publications

(78 citation statements)

References 28 publications

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“…Alternatively, the applied force (WOB) expression presented below Volume proportionality parameter K K value was assumed in previous work to be independent of input variables and to be constant for a given workpiece. For a workpiece of alumina for K was found to be, K = 0.295 as discussed by Liu [11]. The mathematical model developed in Chapter 6 of this discussion also assumed a constant value for K for each type of rock.…”

Section: Mathematical Model Validationmentioning

confidence: 98%

“…This volume is simplified to two tetrahedron volume of ABCD as shown in Figure 15 as follow as discussed by Liu [11]. Where S a ≡ abrasive particle length (equal for 12 sides of the octahedron shape) C a ≡ abrasive particles concentration A o ≡ area of core drill end face / cross section 1 = 3 10 −2 Dimensionless constant ( is the density of abrasive material, g/mm 3 , ρ = 3.52x1 for diamond)…”

Section: Materials Removal Rate For One Abrasive Particle (Mrr P )mentioning

confidence: 99%

“…Nie można odnal odwołania.. . Schematic diagram of material removal in brittle fracture mode induced by the abrasive particle process, Zhang [15] where: K -constant proportionality due to interrelations among abrasive particles, Liu [11] The particle material removal rate (MRR a ) is the product of the fracture zone actual volume times the ultrasonic frequency. By substituting the values of L s in actual volume (V) above, the particle material removal rate could be calculated as:…”

Section: Materials Removal Rate For One Abrasive Particle (Mrr P )mentioning

confidence: 99%

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Rop Mathematical Model of Rotary-Ultrasonic Core Drilling of Brittle Material

Horne¹

2017

Adv. Sci. Technol. Res. J.

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The results from the Phoenix mission led scientists to believe it is possible that primitive life exists below the Martian surface. Therefore, drilling in Martian soil in search for organisms is the next logical step. Drilling on Mars is a major engineering challenge due to the drilling depth requirement and extreme environment condition. Mars lacks a thick atmosphere and a continuous magnetic field that shield the planet's surface from solar radiation and solar flares. As a result, the Martian surface is sterile and if life ever existed, it must be found below the surface. In 2001, NASA's Mars Exploration Payload Advisory Group proposed that drilling should be considered as a priority investigation on Mars in an effort of finding evidence of extinct or extant life. The results from the Curiosity mission suggested drilling six meters deep in the red planet in search for life. Excavation tools deployed to Mars so far have been able to drill to a maximum depth of 6.5 cm. Thus, the drilling capabilities need to be increased by a factor of approximately 100 to achieve the goal of drilling six meters deep. This requirement puts a demand on developing new and more effective technologies to reach this goal. Previous research shows evidence of a promising drilling mechanism in rotary-ultrasonic for what it offers in terms of high surface quality, faster rate of penetration and higher material removal rate. This research addresses the need to understand the mechanics of the drill bit tip and rock interface in rotary-ultrasonic drilling performance of one drill bit at a time drilling in three types of rocks that vary in strength. A mathematical model identifying all contributing independent parameters, such as drill bit design parameters, drilling process parameters, ultrasonic wave amplitude and rocks' material properties, that have effect on rate of penetration is developed. Analytical and experimental results under ambient condition are presented to show the effect of the variation of different parameters on rate of penetration performance as a first step of the investigation. It was found that the speed and WOB have significant effect on ROP while the rest of the parameter have very little or no effect.

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Section: Mathematical Model Validationmentioning

confidence: 98%

Section: Materials Removal Rate For One Abrasive Particle (Mrr P )mentioning

confidence: 99%

Section: Materials Removal Rate For One Abrasive Particle (Mrr P )mentioning

confidence: 99%

See 1 more Smart Citation

Rop Mathematical Model of Rotary-Ultrasonic Core Drilling of Brittle Material

Horne¹

2017

Adv. Sci. Technol. Res. J.

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“…Zhang et al [14] established a theoretical model to predict the cutting force of rotary ultrasonic drilling engineering for ceramics. Liu et al [15] developed a rotary ultrasonic drilling force model based on the brittle fracture theory. The shape of the diamond grit was assumed octahedron.…”

Section: Introductionmentioning

confidence: 99%

“…In previous study and literature review [1][2][3][4][5][6][7][8][9][10][11][12][13][14][15][16][17], it is found that there was main focus on machining ceramics and its related composite materials. The research work on rotary ultrasonic drilling of CFRP materials is rare especially on CFRP-T700.…”

Section: Introductionmentioning

confidence: 99%

Development of a cutting force prediction model based on brittle fracture for carbon fiber reinforced polymers for rotary ultrasonic drilling

Yuan

Zhang

Amin

et al. 2015

Int J Adv Manuf Technol

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Carbon fiber reinforced polymers (CFRP) T700 have got increasing demand in the aerospace industry due to their high specific strength, specific stiffness, and other unique properties. Due to their inhomogeneous, anisotropic, and thermal properties, it is challenging to achieve desired accuracy and to avoid from delamination, chip-off, cracking, and burning especially in the drilling process. The cutting force is the critical parameter which is required to minimize in order to drill a hole with better accuracy and minimize defects. In this research, the brittle fracture approach was adopted and a cutting force model was developed for CFRP-T700 based on the rotary ultrasonic drilling (RUD) process. The experimental RUD was carried out on CFRP-T700 material and found that the feed rate and spindle speed are two main parameters that affect the cutting force in RUD. The cutting force data obtained from the model and experimental setup were then analyzed and found that there is small variation even below 10 % (max value of variation is 8.5 % and the average value is 0.49 %) between simulated and measured values. So, the developed cutting force model was validated and found robust. Also, it was found that with four times increase of feed rate, there is also an increase of material removal rate (MRR) four times with the decrease in the cutting force. Moreover, this model will be much helpful to keep cutting force within limits through the optimal set of parameters as feed rate and spindle speed without extensive experimentation of such costly materials.

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Process of Ultrasonic Machining

Cong

Pei

2014

Handbook of Manufacturing Engineering and Technology

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A cutting force model for rotary ultrasonic machining of brittle materials

Cited by 189 publications

References 28 publications

Rop Mathematical Model of Rotary-Ultrasonic Core Drilling of Brittle Material

Rop Mathematical Model of Rotary-Ultrasonic Core Drilling of Brittle Material

Development of a cutting force prediction model based on brittle fracture for carbon fiber reinforced polymers for rotary ultrasonic drilling

Process of Ultrasonic Machining

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