Characterization of material removal in ultrasonically assisted grinding of SiCp/Al with high volume fraction

Dong, Zhigang; Zheng, Feifei; Zhu, Xianglong; Kang, Renke; Bi, Zhongnan; Liu, Zhiqiang

doi:10.1007/s00170-017-0676-4

Cited by 39 publications

(9 citation statements)

References 27 publications

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“…In this study, a self-built 3-axis CNC machining center equipped with UAVM capabilities was adopted for the CM and UAVM. As illustrated in Figure 2(a), the machining system built by Dong et al [19] mainly consists of a spindle, an ultrasonic tool holder, and an end mill. In this machining system, the ultrasonic tool holder mounted on the front of the spindle is driven by an ultrasonic actuator inside the tool holder, while the ultrasonic vibration mode is controlled by an external ultrasonic generator which is connected to the ultrasonic vibration milling set by a power transmission set.…”

Section: Machining Setup and Proceduresmentioning

confidence: 99%

Surface Integrity of Ultrasonically-Assisted Milled Ti6Al4V Alloy Manufactured by Selective Laser Melting

Guo

Jiang

et al. 2021

Chin. J. Mech. Eng.

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The Ti6Al4V parts produced by the existing selective laser melting (SLM) are mainly confronted with poor surface finish and inevitable interior defects, which substantially deteriorates the mechanical properties and performances of the parts. In this regard, ultrasonically-assisted machining (UAM) technique is commonly introduced to improve the machining quality due to its merits in increasing tool life and reducing cutting force. However, most of the previous studies focus on the performance of UAM with ultrasonic vibrations applied in the tangential and feed directions, whereas few of them on the impact of ultrasonic vibration along the vertical direction. In this study, the effects of feed rate on surface integrity in ultrasonically-assisted vertical milling (UAVM) of the Ti6Al4V alloy manufactured by SLM were systemically investigated compared with the conventional machining (CM) method. The results revealed that the milling forces in UAVM showed a lower amplitude than that in CM due to the intermittent cutting style. The surface roughness values of the parts produced by UAVM were generally greater than that by CM owing to the extra sinusoidal vibration textures induced by the milling cutter. Moreover, the extra vertical ultrasonic vibration in UAVM was beneficial to suppressing machining chatter. As feed rate increased, surface microhardness and thickness of the plastic deformation zone in CM raised due to more intensive plastic deformation, while these two material properties in UAVM were reduced owing to the mitigated impact effect by the high-frequency vibration of the milling cutter. Therefore, the improved surface microhardness and reduced thickness of the subsurface deformation layer in UAVM were ascribed to the vertical high-frequency impact of the milling cutter in UAVM. In general, the results of this study provided an in-depth understanding in UAVM of Ti6Al4V parts manufactured by SLM.

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Section: Machining Setup and Proceduresmentioning

confidence: 99%

Surface Integrity of Ultrasonically-Assisted Milled Ti6Al4V Alloy Manufactured by Selective Laser Melting

Guo

Jiang

et al. 2021

Chin. J. Mech. Eng.

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“…In order to make the nut lighter, square holes need to be machined on its side, as shown in Figure 1. However, the SiC particles in SiCp/Al make its machining difficult [3]. Electrical discharge machining (EDM) is a method of processing materials using the heat generated by electrical discharge, so the hardness has little effect on the processing effect [4].…”

Section: Introductionmentioning

confidence: 99%

Research on Ultrasonic Vibration Assisted Electrical Discharge Machining SiCp/Al Composite

Gao

Xing

et al. 2021

Preprint

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In this paper, ultrasonic-vibration assisted electrical discharge machining (UEDM) is used to process SiCp/Al composite materials in order to achieve a higher material removal rate (MRR) and lower surface roughness, width overcut, and relative tool wear rate (RTWR). FLUENT software was used to simulate the gap flow field. The simulation results of the gap flow field show that the ultrasonic vibration of the tool electrode is conducive to the removal of chips, which makes the discharge more stable and improves the machining efficiency. Based on the single factor experiment, the effects of peak current, reference voltage, pulse width, and pulse interval on MRR, surface roughness, width overcut, and RTWR of the workpiece are studied. Then, based on the orthogonal experiment, the grey relational analysis method was used to optimize the process parameters, and the order of the influence of the 4 process indicators on the comprehensive performance and the optimal processing parameter combination was obtained. The reliability of the process optimization was verified with experiments.

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“…Machinability of particle-reinforced metal matrix composites has been extensively studied [1][2][3]. Dong et al [4] studied the grinding mechanisms of high-volume fraction SiCp/Al composites by ultrasonically assisted grinding with an electroplated diamond wheel. eir study shows that material removal in grinding of SiCp/Al composites is dominated by SiC particle fracture.…”

Section: Introductionmentioning

confidence: 99%

Study on Grinding Mechanism of Brake Pad with Copper Matrix Composites for High-Speed Train

Sangwoo

Wang

Sun

et al. 2019

Advances in Materials Science and Engineering

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e processing mechanism of copper matrix composites is very complex, for the particle phase and lubricating phase are randomly distributed in the copper matrix phase, and the characteristics of the three phases are completely different. Aiming at understanding the chip formation and the influence of each phase of the material on the workpiece surface morphology, a single abrasive grain cutting experiment is carried out. Experiment results show that the cutting force increases with the increase in the cutting depth, but the increase amplitude is smaller. Extrusion of the abrasive particles causes plastic deformation of the copper matrix phase and brittle fracture of the particle phase and graphite phase. It results in the defects on the groove surface, such as pits, collapses and cracks, and holes. e brittle fracture of the graphite phase and the breaking and falling off of the particle phase block the plastic deformation of the copper alloy, which makes the copper alloy not forming ductile chips. e chip is mainly powdery. It shows that the brittle fracture is the main removal form of the brake pad material. e copper matrix phase on the surface of the groove produces obvious plastic deformation. e plastic deformation at the bottom is larger and has a certain degree of fibrosis appearing.

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Characterization of material removal in ultrasonically assisted grinding of SiCp/Al with high volume fraction

Cited by 39 publications

References 27 publications

Surface Integrity of Ultrasonically-Assisted Milled Ti6Al4V Alloy Manufactured by Selective Laser Melting

Surface Integrity of Ultrasonically-Assisted Milled Ti6Al4V Alloy Manufactured by Selective Laser Melting

Research on Ultrasonic Vibration Assisted Electrical Discharge Machining SiCp/Al Composite

Study on Grinding Mechanism of Brake Pad with Copper Matrix Composites for High-Speed Train

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