Effect of process parameters on micro-textured surface generation in feed direction vibration assisted milling

Shen, Xuehui; Shi, Yilun; Zhang, J.H.; Zhang, Q.J.; Tao, Guocan; Bai, Lijuan

doi:10.1016/j.ijmecsci.2019.105267

Cited by 40 publications

(11 citation statements)

References 43 publications

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“…Besides the machining mode based on VAM, machining parameters must be set accordingly, affecting the process of obtaining a low Ra value for the processed product. A comprehensive study through mathematical modeling can be conducted to predict the effect of machining parameters and machining mode (VAM) which each combination affects the Ra value of the product [25]. The effect of vibration in three levels (high, medium and low) varies the wear rate of the tool and workpiece where high vibration level allows to obtain low Ra value of the material [26].…”

Section: Introductionmentioning

confidence: 99%

Numerical modeling and experimental evaluation of machining parameters for 2-dimensions ultrasonic-assisted micro-milling at low and high-speed machining

et al. 2022

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Vibration assisted machining (VAM) is one of the hybrid machining processes for improving the machined surface quality. VAM performance is mainly influenced by the combination of machining and vibration control parameters, where surface roughness value (Ra) became the benchmarking indicator. It is difficult to determine the optimum parameter combination to produce high precision products, especially for micro-milling, due to the interconnected correlation among parameters. The benefits of high-speed machining with VAM are high material removal rate and shorter machining time than low-speed machining. VAM operation at high-speed machining is still limited due to the high possibility of chatter occurrence. Therefore, this research aims to evaluate the 2D VAM resonant performance at low-speed and high-speed machining, operated at ultrasonic vibration and amplitude below one μm. The mathematical model and experimental evaluate the vibration effect based on machining mode, amplitude, and spindle speed variation. The mathematical modelling and experiment result complement each other, where the mathematical model can characterize the effect of resonant vibration, amplitude, and spindle speed increment on the tool path trajectory. The 2D resonant vibration at the feed direction causes interrupting cutting and transforms the tool path trajectory from linear to wavy. The mathematical model and experiment result show the dominant influence of spindle speed and feed rate on the toolpath trajectory and Ra, where low spindle speed and feed rate result in better machine surface roughness. The low-speed machining with VAM results in Ra value between 0.1–0.155 μm, which is below the high-speed machining result, between 0.2–0.38 μm

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Section: Introductionmentioning

confidence: 99%

Numerical modeling and experimental evaluation of machining parameters for 2-dimensions ultrasonic-assisted micro-milling at low and high-speed machining

et al. 2022

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“…As a feasible way to conserve oil and debris on contact surfaces, surface textures have been researched over past decades and widely used in many applications [1], such as vibration cutting tools [2], mechanical seals [3], gas face seals [4], slipper bearing [5], thrust bearing [6], piston rings [7], and medical devices [8,9]. These researches showed the applying of surface textures can reduce wear and increase load carrying capacity, which is helpful to prolong service lives of mechanical components, save energy and protect environment.…”

Section: Introductionmentioning

confidence: 99%

An optimization research on groove textures of a journal bearing using particle swarm optimization algorithm

Zhang

Liu

Zhao

2021

Mechanics & Industry

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This study aims to optimize the distributions of groove textures in a journal bearing to reduce its friction coefficient. Firstly, A lubrication model of a groove textured journal bearing is established, and the finite difference and overrelaxation iterative methods are used to numerically solve the model. Then, the friction coefficient is adopted as the fitness function and the groove lengths are optimized by particle swarm optimization (PSO) algorithm to evolve the optimal distributions. Furthermore, the effects of eccentricity ratios and rotary speeds on optimal distributions of groove textures are also discussed. The numerical results show the optimal distributions of groove textures are like trapeziums under different eccentricity ratios and rotary speeds, and the trapeziums become slenderer with increasing of eccentricity ratios. It is also found that the reductions of friction coefficients by optimal groove textures are more significant under lower eccentricity ratios. Briefly, this study may provide guidance on surface texture design to improve the tribological performance of journal bearings.

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“…Hybrid micro-milling technologies try to fuse the advantages of the mechanical micro-milling and another advanced technology to-more or less-increase (i)-(iv) or decrease (v)-(vii) properties of the process [285]. Ultrasonic vibration-assisted micro-machining is a promising novel technology, which is able to decrease the cutting force, burr formation and surface roughness, compared to the mechanical micro-milling [236,[286][287][288]. Furthermore, the wettability of the micro-machined surfaces can be more advantageous, if the cutting tool or the workpiece is vibrated in an optimised ultrasonic frequency.…”

Section: Future Trends and Outlookmentioning

confidence: 99%

A review on micro-milling: recent advances and future trends

Balázs

Geier

Takács

et al. 2020

Int J Adv Manuf Technol

134

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Recently, mechanical micro-milling is one of the most promising micro-manufacturing processes for productive and accurate complex-feature generation in various materials including metals, ceramics, polymers and composites. The micro-milling technology is widely adapted already in many high-tech industrial sectors; however, its reliability and predictability require further developments. In this paper, micro-milling related recent results and developments are reviewed and discussed including micro-chip removal and micro-burr formation mechanisms, cutting forces, cutting temperature, vibrations, surface roughness, cutting fluids, workpiece materials, process monitoring, micro-tools and coatings, and process-modelling. Finally, possible future trends and research directions are highlighted in the micro-milling and micro-machining areas.

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Effect of process parameters on micro-textured surface generation in feed direction vibration assisted milling

Cited by 40 publications

References 43 publications

Numerical modeling and experimental evaluation of machining parameters for 2-dimensions ultrasonic-assisted micro-milling at low and high-speed machining

Numerical modeling and experimental evaluation of machining parameters for 2-dimensions ultrasonic-assisted micro-milling at low and high-speed machining

An optimization research on groove textures of a journal bearing using particle swarm optimization algorithm

A review on micro-milling: recent advances and future trends

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