An investigation of cutting mechanics in 2 dimensional ultrasonic vibration assisted milling toward chip thickness and chip formation

Ibrahim, Rosziati; Rafai, Noor Hakim; Rahim, Erween Abd; Kamaruddin, Sharul Ashikin; Ding, Hui; Cheng, Kai

doi:10.1088/1757-899x/100/1/012057

Cited by 18 publications

(10 citation statements)

References 4 publications

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“…The higher frequency of cutting, the more chances there is of the tool cutter in one particular area reducing the peak and valley to obtain a good surface result. Rasidi and Ding found the 2D UVAM was helping to cut the crest of the surfaces into smaller pieces while opposing the frequency and amplitude thus, eliminated by the alternating cycles phenomena [5]. From this, we observe that the good surface is made by cutting the crests and peak on the surface with the vibratory tool.…”

Section: Cmme 2016 Imentioning

confidence: 68%

An Experimental Investigation of Cutting Temperature and Tool Wear in 2 Dimensional Ultrasonic Vibrations Assisted Micro-Milling

Ibrahim

Rahim

et al. 2017

MATEC Web Conf.

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Abstract. Two dimensional Ultrasonic vibration assisted milling (2D UVAM) well knows process that involved in high tech system to generate ultra range of frequency applied to the milling process. More industries nowadays become aware taking this opportunity to improve their productivity without decreasing their product accuracies. This paper investigate a comparative machining between UVAM and conventional machining (CM) in tool wear and cutting temperature in milling process. Micro amplitude and sine wave frequency will be generate into the workpiece jig by piezo-actuator. Thus, creating a micro gap that allow heat remove effectively with the chip produces. A more complex tool trajectory mechanics of 2D UVAM has been found during this research. The approaching the tool tip into the workpiece surfaces is affected by the amplitude displacement along the frequency applied. It is found that the tool wear was reduce and surface roughness improvement by applying the 2D UVAM compared to the CM when choosing the optimum amplitude and appropriate frequency.

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Section: Cmme 2016 Imentioning

confidence: 68%

An Experimental Investigation of Cutting Temperature and Tool Wear in 2 Dimensional Ultrasonic Vibrations Assisted Micro-Milling

Ibrahim

Rahim

et al. 2017

MATEC Web Conf.

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“…Ping Guo et al Proposed and designed a new type of ultrasonic vibrator for elliptical vibration deformation, which uses the flexure hinge structure to complete the coupling of twodimensional vibration, and verified the feasibility of the device through experiments [2]. Due to the low vibration intensity of non-resonant devices, they are mainly used in the low frequency field, and focus on the design of flexible vibration structures [3][4][5].In terms of ultrasonic assisted milling device, at present, more research focuses on the development of ultrasonic vibration tool holder to realize ultrasonic milling [6][7][8][9][10][11][12]. Although this idea can be more effectively combined with actual production, for scientific research purposes, using ultrasonic vibration device to drive workpiece vibration to realize ultrasonic milling can undoubtedly save the cost of scientific research.…”

Section: Introductionmentioning

confidence: 96%

Investigation of tool-workpiece contact rate and milling force in elliptical ultrasonic vibration-assisted milling

Zhu

Yang

et al. 2021

Int J Adv Manuf Technol

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Elliptical ultrasonic vibration assisted milling (EUVAM) is widely used as an efficient processing method for hard-to-machining materials such as titanium alloy, superalloy, and hard-brittle materials. To uncover the mechanism of the intermittent cutting characteristics in EUVAM, the tool-workpiece contact rate model is developed by combining with the kinematic relationship between the tool edge and the workpiece in the process. According to the analysis of the contact rate model, the phenomenon that the contact rate increases rapidly with the time-varying tooth position angle in onedimensional ultrasonic vibration assisted milling can be improved in EUVAM. In addition, considering the variation of window function and undeformed cutting thickness, a force model is established. And the experiment of EUVAM is performed to verify the model of ultrasonic milling force, and the influence of process parameters (amplitude, cutting speed, feed rate and cutting depth) on ultrasonic milling force is also analyzed.

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“…Nowadays, EDM applied in many field of industries such as in automobile industry, chemical industry and aerospace industry. The reason is manufacturing process on conduct electricity materials was freedom by its hardness or toughness in EDM operation and also for many types of machining [3,4]. During EDM operation, the partial ionization of the workpiece will cause debris formed in electrode to workpiece spacing.…”

Section: Introductionmentioning

confidence: 99%

Design and Investigate of Flushing System for Electrical Discharge Machining (EDM) Application

Rachmat,

Ibrahim,

Ming

et al. 2020

IJIE

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Electrical Discharge Machining (EDM) is high precision machining process in which no actual contact between the workpiece and electrode during sparking. Dielectric fluid play a role as flushing medium and semiconductor between workpiece and electrode to stabilization and controlled spark gap ionization condition. In real condition, nozzle flushing system in EDM machine not able to complete remove debris formed during machining and affect the machining performance. Improper flushing due to lack of guideline at setup position of nozzle and inlet pressure caused low material removal rate, irregular tool and higher cost on raw material. To overcome this problem, the design and investigate of flushing system in EDM application is required. The design and investigation undergo by simulation of ANSYS Computational Fluid Dynamics (CFD) with a virtual experiment to accurate prediction of flushing performance. The influence of nozzle size and inlet pressure supplied on flushing efficiency were analyzed to avoid improper flushing on die-sinking EDM process. The simulation and experiments clarified that the higher inlet pressure, P=0.20 bar and larger nozzle diameter, D=6mm resulting in higher total pressure which is 2647.16 Pa. Furthermore, the streamline of velocity and eddy viscosity contour in the work tank using to analyze the turbulence zone by nozzle flushing obtained by the CFD analysis. The condition in case 5 (D=5mm, P=0.15 bar) is more efficiency on debris removal rate based on the result of high total pressure on machining zone and eddy viscosity contour showed the turbulence zone only formed area near to outlet of system. The model results have been shown good agreement with experiment and co-relation data.

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An investigation of cutting mechanics in 2 dimensional ultrasonic vibration assisted milling toward chip thickness and chip formation

Cited by 18 publications

References 4 publications

An Experimental Investigation of Cutting Temperature and Tool Wear in 2 Dimensional Ultrasonic Vibrations Assisted Micro-Milling

An Experimental Investigation of Cutting Temperature and Tool Wear in 2 Dimensional Ultrasonic Vibrations Assisted Micro-Milling

Investigation of tool-workpiece contact rate and milling force in elliptical ultrasonic vibration-assisted milling

Design and Investigate of Flushing System for Electrical Discharge Machining (EDM) Application

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