Groove bottom material removal mechanism and machinability evaluation for longitudinal ultrasonic vibration–assisted milling of Al-50wt% Si alloy

Jing, Lei; Niu, Qiulin; Yue, Wenhui; Rong, Jie; Gao, Hang; Tang, Siwen

doi:10.1007/s00170-023-11548-1

Cited by 3 publications

(1 citation statement)

References 39 publications

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“…A three-degree-of-freedom (3-DOF) piezoelectric transducers can generate elliptical ultrasonic vibration and longitudinal ultrasonic vibration independently and can be used to assist milling and drilling [1], respectively. By selecting appropriate elliptical [2][3][4][5][6] or longitudinal [7][8][9][10] vibration parameters, the cutting force and temperature in machining can be greatly reduced, and the surface quality of the workpiece can be improved. Therefore, it is an important component for assisting cutting.…”

Section: Introductionmentioning

confidence: 99%

Structural Optimization Study on a Three-Degree-of-Freedom Piezoelectric Ultrasonic Transducer

Wu,

Zhang,

et al. 2024

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A three-degree-of-freedom (3-DOF) piezoelectric ultrasonic transducer is a critical component in elliptical and longitudinal ultrasonic vibration-assisted cutting processes, with its geometric structure directly influencing its performance. This paper proposes a structural optimization method based on a convolutional neural network (CNN) and non-dominated sorting genetic algorithm II (NSGA2). This method establishes a transducer lumped model to obtain the electromechanical coupling coefficients (X-ke and Z-ke) and thermal power (X-P) indicators, evaluating the bending and longitudinal vibration performance of the transducer. By creating a finite element model of the transducer with mechanical losses, a dataset of different transducer performance parameters, including the tail mass, piezoelectric stack, and dimensions of the horn, is obtained. Training a CNN model with this dataset yields objective functions for the relationship between different transducer geometric structures and performance parameters. The NSGA2 algorithm solves the X-ke and Z-ke objective functions, obtaining the Pareto set of the transducer geometric dimensions and determining the optimal transducer geometry in conjunction with X-P. This method achieves simultaneous improvements in X-ke and Z-ke of the transducer by 22.33% and 25.89% post-optimization and reduces X-P to 18.97 W. Furthermore, the finite element simulation experiments of the transducer validate the effectiveness of this method.

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Section: Introductionmentioning

confidence: 99%

Structural Optimization Study on a Three-Degree-of-Freedom Piezoelectric Ultrasonic Transducer

Wu,

Zhang,

et al. 2024

Actuators

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Study on PCD tool wear in pulsed laser assisted turning Al-50wt% Si alloy

Liu,

Liang,

et al. 2025

Materials Today Communications

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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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Groove bottom material removal mechanism and machinability evaluation for longitudinal ultrasonic vibration–assisted milling of Al-50wt% Si alloy

Cited by 3 publications

References 39 publications

Structural Optimization Study on a Three-Degree-of-Freedom Piezoelectric Ultrasonic Transducer

Structural Optimization Study on a Three-Degree-of-Freedom Piezoelectric Ultrasonic Transducer

Study on PCD tool wear in pulsed laser assisted turning Al-50wt% Si alloy

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

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