Evaluation of micro-textured tool performance in ultrasonic elliptical vibration-assisted turning of 304 stainless steel

Usman, Mustapha Mukhtar; Zou, Ping; Yang, Zhenyu; Lin, Tianyu; Muhammad, Isyaku

doi:10.1007/s00170-022-09539-9

Cited by 10 publications

(5 citation statements)

References 32 publications

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“…As shown in Figure 2, the relationship between shear force, friction force, and resultant force is as follows (7):…”

Section: Milling Burr Size Model Establishmentmentioning

confidence: 99%

“…In Formula (7), Fs is the shear force, Fr is the resultant force, Ff is the frictional force, τs is shear strength, As is the shear area, β is the friction angle, γ0 is the front corner, and φ is cut angle.…”

Section: Milling Burr Size Model Establishmentmentioning

confidence: 99%

“…It has been proven that both the characteristic parameters of microgroove size and cutting parameters have a significant impact on cutting performance. Usman Mustapha Mukhtar [7] and Ali Shafahat [8] have both studied it in the field of unconventional cutting. The former studied the cutting performance of micro-textured cutting tools on the front face under ultrasonic elliptical vibration cutting, demonstrating that the combined effect of ultrasonic elliptical vibration cutting mechanism and tool texturing technology can significantly improve the significant machining efficiency of ultrasonic elliptical vibration cutting.…”

Section: Introductionmentioning

confidence: 99%

See 2 more Smart Citations

Analysis of Surface Characteristics of Titanium Alloy Milling with Ball-End Milling Cutters Based on Mesoscopic Geometric Features

Tong,

Wang,

Wang

et al. 2024

Coatings

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In order to further reduce the height of burrs on the surface of the workpiece when milling titanium alloy with ball-end milling cutters and optimize the quality of the workpiece, this article takes the mesoscopic geometric feature of ball-end milling cutters as the research object and establishes the theoretical relationship between the mesoscopic geometric feature parameters and the height of titanium alloy burrs during milling. A milling test platform was built to explore the influence of micro-texture, blunt edge single factor, and their interaction with cutting parameters on the force-thermal characteristics and workpiece burr in the milling process. The influence mechanism was revealed, and the prediction model was established. The results show that the ball-end milling cutter with mesoscopic geometric features was able to suppress burrs, and the burr height was reduced by 21% compared with the non-textured milling cutter. The micro-texture reduced the contact area and improved the heat dissipation conditions, thereby reducing the force-thermal characteristics and thus inhibiting the formation of some burrs. The blunt edge can disperse the stress, diffuse the local heat in the tool–chip contact area, and reduce the burr height. In the interaction test considering cutting parameters, the interaction between R and ap was significant. The optimized parameters based on the simulated annealing algorithm were as follows: the radius of the blunt edge was 33.242 μm, the distance between the texture and the edge was 114.621 μm, the texture diameter was 59.820 μm, the texture spacing L1 was 131.410 μm, the cutting depth ap was 0.310 mm, the cutting speed V was 140.019 mm/min, and the feed f was 60 μm/z. This provides a basis for the study of strengthening the tool to suppress burr size.

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“…As shown in Figure 2, the relationship between shear force, friction force, and resultant force is as follows (7):…”

Section: Milling Burr Size Model Establishmentmentioning

confidence: 99%

Section: Milling Burr Size Model Establishmentmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

See 1 more Smart Citation

Analysis of Surface Characteristics of Titanium Alloy Milling with Ball-End Milling Cutters Based on Mesoscopic Geometric Features

Tong,

Wang,

Wang

et al. 2024

Coatings

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show abstract

“…During machining, the quality of the surface treatment is an important requirement, therefore the choice of optimized cutting parameters is very important for checking the required surface quality [20][21][22]. Machining difficult-to-machine materials such as AISI304 usually leads to poor surface finish, irregular tool wear and premature tool failure [23][24]. This is mainly due to high strength, high fracture toughness, high resistance to fatigue and corrosion.…”

Section: Surface Integrity and Tool Wearmentioning

confidence: 99%

Machining of Austenitic Stainless Steels - the Influence of Various Factors on the Machining Result

Čička,

Turisová,

Kóča

et al. 2023

Acta Mechanica Slov.

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In today's world, AISI stainless steel accounts for almost half of the world's production and consumption for industrial purposes. Stainless steel is the most popular alloy widely used in the production of parts due to its properties such as high strength, high corrosion resistance or high ductility, but they are hard materials to machine from the metallurgical aspect, such as low thermal conductivity, chip formation, cutting tool wear. The focus of the paper is on machining stainless steel -a review, where various machining problems are discussed by different researchers and their probable solution can provide help to reduce tool wear, increase corrosion resistance, high surface quality finish by reducing machining complexity. The article also provides a detailed specification of the most important factors that significantly affect the lifespan of tools used for machining austenitic stainless steel.

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“…In each vibration cycle, the complete separation of tool and material is conducive to the entry of cutting fluid into the cutting zone, achieving better heat dissipation and lubrication, thereby reducing tool wear and improving cutting surface quality [8][9][10]. The diamond tool can also be applied to the cutting of ferrous metals [11,12], and improve the machinability of hard and brittle materials [13,14]. However, intermittent cutting can also lead to periodic changes in cutting force, resulting in the chatter of horn and tool in UEVC device.…”

Section: Introductionmentioning

confidence: 99%

Cutting Chatter in Ultrasonic Elliptical Vibration Cutting and Its Influence on Surface Roughness and Tool Wear

Wang

Pan

et al. 2023

Metals

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Ultrasonic elliptical vibration cutting has a wide range of applications in the field of precision cutting of difficult-to-machine metal materials. However, due to its intermittent cutting characteristics and the weak rigidity of the horn, cutting chatter is prone to occur during its cutting process, which has an important impact on cutting surface quality and tool wear. In this paper, the rigid/viscoplastic rod model is used to simulate the horn in the ultrasonic elliptical vibration cutting device, and the influence factors of the amplitude-frequency response of the horn are analyzed. The influence of cutting speed and cutting depth on cutting chatter was studied by ultrasonic elliptical vibration cutting experiment of tungsten heavy alloy, and the influence of cutting chatter on cutting surface morphology and diamond tool wear was studied. The research shows that cutting speed will change the excitation frequency of the horn, and reasonable cutting speed can inhibit the occurrence of cutting chatter and avoid resonance of the horn. The cutting depth will affect the excitation amplitude and amplify the vibration amplitude when chatter or resonance occurs. The experimental results show that in ultrasonic elliptical vibration cutting of heavy tungsten alloy, chatter suppression can significantly improve the quality of the cutting surface and reduce the wear of diamond tools.

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Evaluation of micro-textured tool performance in ultrasonic elliptical vibration-assisted turning of 304 stainless steel

Cited by 10 publications

References 32 publications

Analysis of Surface Characteristics of Titanium Alloy Milling with Ball-End Milling Cutters Based on Mesoscopic Geometric Features

Analysis of Surface Characteristics of Titanium Alloy Milling with Ball-End Milling Cutters Based on Mesoscopic Geometric Features

Machining of Austenitic Stainless Steels - the Influence of Various Factors on the Machining Result

Cutting Chatter in Ultrasonic Elliptical Vibration Cutting and Its Influence on Surface Roughness and Tool Wear

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