Effect of 3D elliptical ultrasonic assisted boring on surface integrity

Lotfi, Mohammad; Amini, Saeid; Aghayar, Zahra; Sajjady, Sayed Ali; Farid, Ali Akhavan

doi:10.1016/j.measurement.2020.108008

Cited by 23 publications

(9 citation statements)

References 22 publications

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“…This result is consistent with the results of several researches already mentioned in Introduction. [22][23][24] Increasing the vibration amplitude leads to a decrease in the average cutting force in vibration-assisted turning, which is due to the increase in tool separation time and cutting area in the ultrasonic vibration cycle.…”

Section: Resultsmentioning

confidence: 99%

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An investigation on the material removal mechanism, surface porosity, and surface integrity in ultrasonic vibration assisted turning of porous stainless steel 316L

Ghorbani

Nategh

Karafi

2022

Proceedings of the Institution of Mechanical Engineers, Part B:

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The machining of porous materials is commonly accompanied with high and irregular cutting forces, high cutting temperature, poor surface integrity, and severe tool wear. The porous materials are considered difficult to be machined. Porosity reduces the rate of heat transfer; moreover, it impairs the continuous cutting and therefore leads to cyclic loads. The main objective of the present study is to investigate the influence of superimposing ultrasonic vibration to the cutting motion of the cutting tool on the surface integrity of the porous materials. For this purpose, the mechanism of chip removal in vibration assisted machining of porous materials was analyzed and porous stainless steel 316L specimens were machined by ultrasonic vibration assisted turning. It was illustrated by the porosimetry of the machined surfaces that the surfaces machined by conventional turning had higher rate of surface porosity compared with ultrasonic vibration assisted turning. In the latter process, the SEM images of the machined surfaces manifested the existence of a kind of rubbing mechanism and material overlaps, which was attributable to the friction existing between the cutting tool with micro scale reciprocating motion and the surface of the workpiece. The overall impact of imposing ultrasonic vibration to the cutting tool motion in the cutting direction was the achievement of a trade-off between preserving the porosity and improvement of the surface quality. This effect was bolstered by increasing the vibration amplitude.

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Section: Resultsmentioning

confidence: 99%

“…Also many researchers (e.g. Xu et al, 22 Jamshidi and Nategh, 23 Lotfi et al 24 ) have reported that the addition of ultrasonic vibration reduces the cutting force. This leads to a reduction in the tool wear [25][26][27] .…”

Section: Introductionmentioning

confidence: 99%

An investigation on the material removal mechanism, surface porosity, and surface integrity in ultrasonic vibration assisted turning of porous stainless steel 316L

Ghorbani

Nategh

Karafi

2022

Proceedings of the Institution of Mechanical Engineers, Part B:

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“…A multiple regression model was deployed to associate tool life with a surface roughness of work material, the amount of metal removed as well as the vibration of work materials. Lotfi et al (2020) analyzed a threedimensional vibration approach to assess its impact on surface integrity during the boring process. Lawrance et al (2020a) built up an impact damper attached to the boring tool to lessen the tool vibration and enhance the tribological characteristics of the work material.…”

Section: Literature Review 21 Generalmentioning

confidence: 99%

“…An important way that modern manufacturing industries can enhance surface quality through the reduction of roughness in boring operations is to ascertain that the process parameters are first evaluated to properly position each element in its important position (Zhang et al, 2017;Yuvaraju and Nanda, 2018;Melo et al, 2019;Klein et al, 2020;Lotfi et al, 2020). Then, elements with utmost importance should be adequately provided with the necessary resources to achieve an optimal level of performance (Ratnam et al, 2018;Izelu et al, 2019).…”

Section: Introductionmentioning

confidence: 99%

Performance Evaluation of Surface Roughness in the Boring Operation of IS 2062 E250 Plate on CNC Machine Using Combined Entropy-Decision Tree-VIKOR Approach

Abiola

Oke

2021

IJIEM

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In boring E250 B0 steel material, the selection of process parameters is one of the most challenging tasks to achieve. The boring literature lacks understanding and fails to reveal how to select the important boring parameters for utmost resource distribution to the most important parameters. This article proposes a novel method to analyse the importance of parameters in boring to produce utmost surface roughness using the entropy-decision tree-VIKOR approach as a multi-criteria decision-making solution to the choice of process materials for superior surface roughness. The choice parameters include speed, depth of cut, feed and nose radius. The entropy approach was instituted to attain the weight of the diverse parameters. The decision tree approach is deployed through the classification of the parameters as beneficial and non-beneficial and the expected values at each mode evaluated. The desirable weightage is then established and serves as the input to the VIKOR approach. This converts the desirable weightage into unit measures through the best/worst value and weightage evaluation. The individual regrets are then analyzed and the final ranking obtained. Results revealed that the depth of cut is the most important parameter, then nose radius (0.98), feed (0.307) and speed (0), respectively. Therefore, a plan to assign more measures to the depth of cut may be developed and the least resources may be assigned to speed. This detail may be helpful to prepare the annual budgets for the boring operation on the factory floor.

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“…Influence of the vibration on the cutter in X-, Y-, and Z-directionswas shown in Figure 3. Vibration components acted on the cutter in the three directions were expressed as follows (Lotfi et al, 2020;Zeqin et al, 2018)…”

Section: Modeling Of Roundnessmentioning

confidence: 99%

Modeling of tool vibration and its effect on roundness and surface roughness of hole in helical milling of Inconel 718

Rao

Ramesh

2020

Journal of Vibration and Control

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Relative vibration between the cutter and workpiece has an influence on the surface generation and dimensional accuracy. In the present work, prediction models were developed for roundness and surface roughness of hole in terms of amplitude and frequency of tool vibration. The proposed methodology carried out a theoretical investigation on the effect of tool vibration components in X- and Y-directions on the mill cutter end point to estimate hole roundness and surface roughness. Series of helical milling experiments were conducted at different levels of spindle rotational speed, cutter orbital speed, and axial depth of cuts using 10- mm and 8- mm diameter mill cutters on Inconel 718. Predicted values of the roundness and surface roughness of hole were compared with predicted values and verified accuracy of the proposed prediction models. The experimental results indicate a good agreement with the predicted value. At spindle rotational speed of 2000 r/min and cutter orbital speed of 50 r/min, the measured and predicted values of the roundness were found to be almost same as the required roundness. The surface roughness was found to be very less at 50 r/min of cutter orbital speed.

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Effect of 3D elliptical ultrasonic assisted boring on surface integrity

Cited by 23 publications

References 22 publications

An investigation on the material removal mechanism, surface porosity, and surface integrity in ultrasonic vibration assisted turning of porous stainless steel 316L

An investigation on the material removal mechanism, surface porosity, and surface integrity in ultrasonic vibration assisted turning of porous stainless steel 316L

Performance Evaluation of Surface Roughness in the Boring Operation of IS 2062 E250 Plate on CNC Machine Using Combined Entropy-Decision Tree-VIKOR Approach

Modeling of tool vibration and its effect on roundness and surface roughness of hole in helical milling of Inconel 718

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