Analytical model of exit burr height and experimental investigation on ultrasonic-assisted high-speed drilling micro-holes

Zai, Penghui; Tong, Jinglin; Liu, Ziqiang; Zhang, Zhipeng; Song, Chaosheng; Zhao, Bo

doi:10.1016/j.jmapro.2021.06.010

Cited by 29 publications

(9 citation statements)

References 28 publications

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“…Liu et al [22] proposed an improved method for constructing a burr length prediction model, the feasibility of which is verified by several experiments. Zai et al [23] presented an analytical model for the height of micro-holes exit burr to understand the effects of processing parameters on the burr height. These literatures established different analyzed model to investigate burr formation mechanism in simple and rigid workpiece, but for thin-walled workpiece, due to the tool deflection and workpiece deformation, the burr formation process is very complex, and the burr formation mechanism in different position is distinct.…”

Section: Fig 1 Burr Morphology and Naming Formed By Slot Millings On ...mentioning

confidence: 99%

Top Burr Thickness Prediction Model in Milling of Thin-Wall Workpiece considering tool and workpiece deformation

Wang¹,

Zhao²,

Zhang³

et al. 2023

Preprint

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In aviation and weapon industry, aluminum alloy thin-walled workpiece are widely used, and milling is a common manufacturing process for these thin-walled workpiece. In milling, many burrs generate on the entrances and exits of cutting tool on workpiece surface, which affects machining quality, assembly accuracy and produces more seriously tip discharge effect. To investigate the burr formation mechanism, an analyzed model of top burr thickness considering the tool deflection angle and workpiece deformation is proposed to elaborate the burr formation process in milling of thin-walled workpiece. In this process, top burr formation process is analyzed and the burr thickness is expressed by the motion relationship between cutting tools and workpieces. Then, based on energy theory, a top burr thickness predicted model considering the tool deflection angle and workpiece deformation in milling of aluminum alloy thin-walled workpiece is proposed. Subsequently, under the determined milling condition, the top burr thicknesses are calculated for verification. Finally, several milling experiments are carried out for validating the feasibility and effectiveness of the proposed model. Experimental results show that the predicted top burr thicknesses are in good agreement with the measured value in milling, and the prediction accuracy of the top burr thickness by proposed model reached 96.5%.

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Section: Fig 1 Burr Morphology and Naming Formed By Slot Millings On ...mentioning

confidence: 99%

Top Burr Thickness Prediction Model in Milling of Thin-Wall Workpiece considering tool and workpiece deformation

Wang¹,

Zhao²,

Zhang³

et al. 2023

Preprint

Self Cite

View full text Add to dashboard Cite

show abstract

“…Pandey et al [47][47] developed a physics-based force model for ultrasonic-assisted milling of Al6063 alloy by applying acoustic softening. Zhao et al [48] established a model for ultrasonic-assisted drilling of titanium alloy, and the acoustic softening effect was presented. However, the research on force prediction of UVHG for high-volume fraction SiCp/Al composites is still blank.…”

Section: Introductionmentioning

confidence: 99%

Modeling for Ultrasonic Vibration-assisted Helical Grinding of SiC particle-reinforced Al-MMCs

Li¹,

Yuan

Gao³

et al. 2023

Preprint

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Silicon carbide (SiC) particle-reinforced aluminum matrix (SiCp/Al) composites have continuously increased applications in abundant industries due to their superior mechanical properties. However, such composites have issues achieving desired machinability and quality standard due to the presence of SiC particles which is the main hindrance to their applications. In this paper, the methodology of ultrasonic vibration-assisted helical grinding (UVHG) of SiCp/Al composites has been applied to achieve to desired quality and efficiency for such composites. Then a mechanical cutting force model was developed to predict grinding forces. The grinding force was separated into friction force, plastic deformation force, and fracture force on account of the material removal mechanism. The undeformed chip thickness and cross-sectional area were calculated for the grinding force of a single diamond abrasive grit and then extended to the whole tool. By considering the acoustic softening effect of reduction of deformation stress caused by ultrasonic vibration, the acoustic softening coefficient was first proposed in the model to correct the impact of the ultrasonic vibration for properties of SiCp/Al composites. The experimental machining (UVHG) was carried out considering the different groups of experiments. The experimental results found agreed with the predicted values of cutting forces. The prediction deviation of the model was 7.06%, which could provide further guidance for the grinding process optimization of SiCp/Al composites. The novel cutting force predicted model and proposed machining methodology could be applied to machining SiCp/Al composites at the industry level and further research work.

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“…By applying ultrasonic vibration to the tool to remove materials intermittently, the purpose of improving machining efficiency, reducing cutting force and reducing tool wear was realized, which is the characteristic of ultrasonic vibration cutting [1]. Nowadays, ultrasonic vibration cutting has been successfully applied in many processing fields, such as turning [2], milling [3] and drilling [4]. Due to the characteristics of high processing temperature and large cutting force, it is easy to have low processing efficiency and poor surface quality when machining hard and brittle materials such as titanium alloy, ceramics and fiber reinforced composites by traditional cutting methods [5].…”

Section: Introductionmentioning

confidence: 99%

Research on a novel non-uniform and asymmetric ultrasonic vibration system and Machined surface characteristics

Zhao¹,

Wang²,

Wang

et al. 2023

Preprint

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A new type of non-uniform and asymmetric ultrasonic vibration system is proposed and applied to the turning process. The research results show that the design theory of the non-uniform and non-symmetric ultrasonic vibration system is accurate and reliable. The designed non-uniform and non-symmetric ultrasonic vibration system has excellent vibration performance and stability, and the established simulation model can predict surface microstructure accurately. The vibration mode output by the non-uniform and non-symmetric ultrasonic vibration system is longitudinal-bending vibration, and the actual vibration performance is excellent. Compared with conventional cutting, the addition of longitudinal-bending ultrasonic vibration under the same conditions can give the machined surface a microscopic texture structure, reduce surface roughness and water contact angle, and improve the surface wettability. The orthogonal experiment results show that there is a correlation between the machining parameters, surface micro-structure parameters, surface wettability, and surface roughness.

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Analytical model of exit burr height and experimental investigation on ultrasonic-assisted high-speed drilling micro-holes

Cited by 29 publications

References 28 publications

Top Burr Thickness Prediction Model in Milling of Thin-Wall Workpiece considering tool and workpiece deformation

Top Burr Thickness Prediction Model in Milling of Thin-Wall Workpiece considering tool and workpiece deformation

Modeling for Ultrasonic Vibration-assisted Helical Grinding of SiC particle-reinforced Al-MMCs

Research on a novel non-uniform and asymmetric ultrasonic vibration system and Machined surface characteristics

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