Design optimization of ultrasonic vibration cutting tool to generate well-decoupled elliptical trajectory

Yang, Jinchuan; Feng, Pingfa; Zhang, Chenglong; Wang, Jianjian

doi:10.1007/s00170-022-08745-9

Cited by 10 publications

(2 citation statements)

References 36 publications

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“…Due to the minimal mutual interference and the highest decoupling efficiency when the angle between two sets of vibrating waves in two-dimensional space is 90 • [30], the two branches of the D-UEVC device considered in this study are arranged with a 90 • angular layout, as shown in Figure 1. The ultrasonic vibrating waves generated by four pieces of PZT are delivered by an exponential amplitude horn.…”

Section: Mechanistic Analysis Of Double Excitation Elliptical Vibrationsmentioning

confidence: 99%

Developmental and Experimental Study on a Double-Excitation Ultrasonic Elliptical Vibration-Assisted Cutting Device

Hu,

Xin,

Zhang

et al. 2024

Machines

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Ultrasonic elliptical vibration-assisted cutting (UEVC) has been successfully applied in the precision and ultra-precision machining of hard and brittle materials due to its advantages of a low cutting force and minimal tool wear. This study developed a novel double-excitation ultrasonic elliptic vibration-assisted cutting (D-UEVC) device by coupling ultrasonic vibrations in orthogonal dual paths. A two-degree-of-freedom vibration system of the D-UEVC was modeled, form which the elliptical trajectory of the end under different phase angle φ values was derived. The initial dimensions of the D-UEVC device were obtained through theoretical calculations. Subsequently, with the aid of finite element analysis methods, structural dynamic analysis of the device was conducted to obtain the elliptical vibration trajectory under different phase differences of the excitation source. In order to verify the cutting trajectory and cutting performance of the D-UEVC device, a prototype of the device was developed, and a series of vibration performance tests as well as the Inconel 718 cutting experiment were conducted. The experimental results illustrated that the D-UEVC device can achieve the elliptical vibration trajectory at the tool tip with a resonant frequency of 36.5 KHz. The adjustable elliptical vibration trajectories covered a range of ±4 μm in the axial and radial directions. Compared with the surface roughness Ra = 0.36 μm under the conventional cutting, the surface roughness of Inconel 718 under D-UEVC was Ra = 0.215 μm. Thus, the surface quality can be significant improved by utilizing the D-UEVC device.

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Section: Mechanistic Analysis Of Double Excitation Elliptical Vibrationsmentioning

confidence: 99%

Developmental and Experimental Study on a Double-Excitation Ultrasonic Elliptical Vibration-Assisted Cutting Device

Hu,

Xin,

Zhang

et al. 2024

Machines

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“…They assessed the device's performance through experimental research, revealing substantial reductions in tool wear when compared with conventional cutting techniques. Jinchuan Yang et al [26] proposed a method for optimizing ultrasonic elliptical vibration, which solved the difficulties of coupling ultrasonic elliptical vibration and the low controllability of elliptical trajectories. Through experiments, it was proven that the tool designed using this optimization method achieved good elliptical trajectory control and improved cutting performance of the tool.…”

Section: Introductionmentioning

confidence: 99%

Experimental Study on the Roundness of Deep Holes in 7075 Aluminum Alloy Parts by Two-Dimensional Ultrasonic Elliptical Vibration Boring

Yang,

Tong,

Liu

et al. 2023

Micromachines

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The 7075 aluminum alloy deep hole pipe finds extensive applications in the aerospace industry due to its remarkable attributes, such as high strength, exceptional wear resistance, and favorable mechanical properties. However, traditional boring processes for 7075 aluminum alloy deep hole pipes tend to generate elevated cutting forces, potentially leading to deformation issues in these deep holes. In response to these challenges, this study introduces a novel approach involving the use of a two-dimensional ultrasonic elliptical vibration tool. This tool features a single excitation asymmetric structure and aims to enhance the deep hole machining process in 7075 aluminum alloy. The research methodology involved several key steps. First, theoretical analysis and simulation were performed to study the motion trajectory of the cutting edge of the tool. Second, practical experiments were conducted comparing two-dimensional ultrasonic elliptical vibration boring with conventional boring for 7075 aluminum alloy deep hole pipes. The results demonstrate that, in contrast to conventional boring, two-dimensional ultrasonic vibration boring could achieve a maximum reduction of 54.1% and an average reduction of 50.4% in the roundness value of the deep holes. The impact of machining parameters on deep hole roundness is assessed through experimental analysis, leading to the determination of optimal processing parameters. In summary, this experimental research has a certain reference significance for the application of 7075 aluminum alloy deep hole parts in the aerospace field.

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Geometric error measurement of facing head and machining verification on large horizontal boring and milling machine tool

Chen

Liu

2022

Int J Adv Manuf Technol

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Design optimization of ultrasonic vibration cutting tool to generate well-decoupled elliptical trajectory

Cited by 10 publications

References 36 publications

Developmental and Experimental Study on a Double-Excitation Ultrasonic Elliptical Vibration-Assisted Cutting Device

Developmental and Experimental Study on a Double-Excitation Ultrasonic Elliptical Vibration-Assisted Cutting Device

Experimental Study on the Roundness of Deep Holes in 7075 Aluminum Alloy Parts by Two-Dimensional Ultrasonic Elliptical Vibration Boring

Geometric error measurement of facing head and machining verification on large horizontal boring and milling machine tool

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