Effect of ultrasonic vibration on the machining performance and mechanism of hybrid ultrasonic vibration/plasma oxidation assisted grinding

Wu, Hualong; Duan, Wenhong; Sun, Linhe; Zeng, Jing; Li, Sisi; Wang, Qiang; Wu, Yongbo; Chen, Yuhan

doi:10.1016/j.jmapro.2023.03.067

Cited by 12 publications

(12 citation statements)

References 25 publications

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“…Emphasis is placed on investigating the material removal mechanisms during grinding. Wu et al [177] conducted a study on a hybrid machining process involving ultrasonic vibration and plasma oxidationassisted grinding (UPOAG) of Ti-6Al-4V titanium alloy. Researchers have focused on investigating the effects of ultrasonic vibration on the machining characteristics.…”

Section: Hybrid Nontraditional Energy-assisted Grindingmentioning

confidence: 99%

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Nontraditional energy-assisted mechanical machining of difficult-to-cut materials and components in aerospace community: a comparative analysis

Zhao,

Ding

et al. 2024

Int. J. Extrem. Manuf.

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Difficult-to-cut materials such as titanium alloys, high-temperature alloys, metal/ceramic/polymer-matrix composites, hard and brittle materials, as well as geometrically complex components such as thin-walled structures, micro channels and complex surfaces, are widely used in aerospace community. Mechanical machining is the main material removal process and responsible for the vast majority of material removal for aerospace components. Nevertheless, it encounters many problems in terms of severe and rapid tool wear, low machining efficiency, and deteriorated surface integrity. Nontraditional energy-assisted mechanical machining is a hybrid process in which nontraditional energies, e.g., vibration, laser, electric, etc., are applied to improve the machinability of local material and decrease burden of mechanical machining. It provides a feasible and promising way for improving machinability and surface quality, reducing process forces, and prolonging tool life, etc. However, systematic reviews of this technology are lacking with respect to the current research status and development direction. This paper reviews recent progress in nontraditional energy-assisted mechanical machining of difficult-to-cut materials and components in aerospace community. It focuses on the processing principles, material responses under nontraditional energy, resultant forces and temperatures, material removal mechanisms and applications of these processes including vibration-, laser-, electric-, magnetic-, chemical-, cryogenic cooling-, and hybrid nontraditional energies-assisted mechanical machining. Eventually, a comprehensive summary of the principles, advantages and limitations for each hybrid process is provided, and future perspectives on forward design, device development and sustainability of nontraditional energy-assisted mechanical machining processes are discussed.

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Section: Hybrid Nontraditional Energy-assisted Grindingmentioning

confidence: 99%

“…Figure 21. Classification diagram of hybrid nontraditional energy-assisted mechanical machining[176][177][178]. Reproduced from[176].…”

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confidence: 99%

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Nontraditional energy-assisted mechanical machining of difficult-to-cut materials and components in aerospace community: a comparative analysis

Zhao,

Ding

et al. 2024

Int. J. Extrem. Manuf.

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“…In recent years, the introduction of ultrasonic vibration in grinding is a new method to improve the grinding quality of di cult-to-machine materials such as titanium alloys, nickel-based high-temperature alloys, ceramics and other materials in the aerospace industry [18][19][20][21][22][23][24][25][26]. Studies have shown that ultrasonic vibration-assisted grinding (UVAG) can introduce high-frequency micro-amplitude vibration, change the relative motion trajectory between the abrasive grain and the workpiece, so that the relative percentage of abrasive grain rubbing, ploughing, cutting effect changes, which can effectively reduce the grinding force and the grinding temperature, and enhance the integrity of the surface of the workpiece [26][27][28][29][30].…”

Section: Introductionmentioning

confidence: 99%

Wear mechanism of aggregated cBN grains during single-grain ultrasonic vibration-assisted grinding of γ-TiAl alloys

Song,

Zhao,

Ding

et al. 2024

Preprint

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In this study, the wear mechanism of single aggregated cubic boron nitride (AcBN) grain during ultrasonic vibration-assisted grinding is investigated. The single AcBN grinding experiment are conducted under conventional grinding and ultrasonic vibration-assisted grinding on gamma titanium-aluminum intermetallic compounds, and the grain wear mechanism is comprehensively revealed by observing the radial wear height, normal force, average volume pile-up ratio, and morphology evolution of the grains with different maximum undeformed chip thicknesses, grinding speeds, and ultrasonic amplitudes. The experimental results show that the introduction of ultrasonic vibration produces periodic vibration of the workpiece in the tangential direction, which can produce intermittent dissociative behavior and effectively reduce normal force and average volume pile-up ratio of single AcBN grains when grinding, but also makes the instantaneous maximum undeformed chip thickness increase and introduces the periodic impact force, which accelerates the radial wear height of the AcBN grains. In addition, the ultrasonic vibration can effectively reduce the material adhesion in the AcBN grains surface and cause it to continuously undergo micro-fracture has better self-sharpening ability. In addition, excessive ultrasonic amplitude will lead to AcBN grains to occur macro-fracture and the expansion of bond cracks lead to abrasive grains pulling out, losing partial grinding ability.

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“…The design time and manufacturing costs in practical manufacturing processes may thus be effectively reduced [1]. Wu et al (2023) investigated the impact of ultrasonic vibration on the machining performance of titanium alloy experimentally in the hybrid-assisted grinding of ultrasonic vibration/plasma oxidation. In this experiment, a three-axis CNC machining center with an ultrasonic spindle at a frequency of 25 kHz attached to a conductive grinding wheel was utilized to perform ultrasonic vibration.…”

Section: Introductionmentioning

confidence: 99%

Structure Design Improvement and Stiffness Reinforcement of a Machine Tool through Topology Optimization Based on Machining Characteristics

Lin,

Chang

2023

Applied Sciences

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Machining characteristics were applied to topology optimization for machine tool structure design improvement in this study, and the goals of lightweight and high rigidity of the structure were achieved. Firstly, an ultrasonic-assisted grinding experiment was carried out on zirconia to investigate the surface roughness, surface morphology, grinding vibration, and forces. Then, the topology optimization analysis was conducted for structure design improvement, in which the magnitude of the grinding vibration was utilized as the reference for selecting the topology subsystems and the grinding force was used as the boundary conditions of the static analysis in the topology optimization. Hence, columns, bases, and saddles were redesigned for structure stiffness improvement, and the variations in the effective stress, natural frequency, weight, and stiffness of the whole machine tool were compared accordingly. The results showed that the deduced topological shape (model) can make the natural frequency and stiffness of the whole machine tool tend to be stable and convergent with a weight retention rate more than 75% as the design constraint. The subsystem structures with larger effective stress distributions were designated for stiffness improvement in the design. At the same time, the topological shape (model) was also employed in the design for weight reduction, focusing on minimizing redundant materials within the structure. In contrast to the consistency of the modal shapes before and after topological analysis, the sequential number of the modal mode of the machine tool model after topological analysis was advanced by two modes relative to those of the original situation, which means the original machine tool may be out of its inherently resonant frequency range. Also, the natural frequencies corresponding to each mode had an increasing tendency, and the maximum increase was 110.28%. Furthermore, the stiffness of the machine tool also increased significantly, with a maximum of 355.97%, leading to minor changes of the machine tool’s weight. These results confirm that the topology optimization based on machining characteristics proposed in this study for structure redesign improvement and stiffness enhancement is effective and feasible.

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Effect of ultrasonic vibration on the machining performance and mechanism of hybrid ultrasonic vibration/plasma oxidation assisted grinding

Cited by 12 publications

References 25 publications

Nontraditional energy-assisted mechanical machining of difficult-to-cut materials and components in aerospace community: a comparative analysis

Nontraditional energy-assisted mechanical machining of difficult-to-cut materials and components in aerospace community: a comparative analysis

Wear mechanism of aggregated cBN grains during single-grain ultrasonic vibration-assisted grinding of γ-TiAl alloys

Structure Design Improvement and Stiffness Reinforcement of a Machine Tool through Topology Optimization Based on Machining Characteristics

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