Investigation on ultrasonic elliptical vibration boring of deep holes with large depth–diameter ratio for high-strength steel 18Cr2Ni4WA

Dong, Guojun; Wang, Lei; Li, Chen; Yu, Yunfeng

doi:10.1007/s00170-020-05531-3

Cited by 21 publications

(12 citation statements)

References 31 publications

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“…To calculate the uncut thickness, firstly, the force model is fitted according to conventional boring experiments and considering Equation (11), and, secondly, the model torque is fitted by the conventional boring experiments under different cutting conditions.…”

Section: Fitting Of Force Model Resultsmentioning

confidence: 99%

“…Once the torque average values of the DoE conventional measurements are estimated, best described in Table 2 Group a, the final stage is to fit the model torque regarding these averages and Equation (11). Figure 10 shows the average measured torque values and the fitting results.…”

Section: Fitting Of Force Model Resultsmentioning

confidence: 99%

“…Regarding boring [11], an apparatus to perform cutting with an elastic movement and superimposed axial vibration [12] to improve the quality of the surface showed good results [13]. Other processes between drilling and boring were discussed, such as the boring trepanning association (BTA) [3], presenting a severe segmentation of the chip; on results [13].…”

Section: Introductionmentioning

confidence: 99%

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Predicted Torque Model in Low-Frequency-Assisted Boring (LFAB) Operations

Veiga¹,

Val²,

Penalva³

et al. 2021

Metals

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A low-frequency-assisted boring operation is a key cutting process in the aircraft manufacturing sector when drilling deep holes to avoid chip clogging based on chip breakage and, consequently, to reduce the temperature level in the cutting process. This paper proposes a predicted force model based on a commercial control-supported chip breaking function without external vibration devices in the boring operations. The model was fitted by conventional boring measurements and was validated by vibration boring experiments with different ranges of amplitude and frequency. The average prediction error is around 10%. The use of a commercial function makes the model more attractive for the industry because there is no need for intrusive vibration sensors. The low-frequency-assisted boring (LFAB) operations foster the chip breakage. Finally, the model is generic and can be used for different cutting materials and conditions. Roughness is improved by 33% when vibration conditions are optimal, considered as a vibration amplitude of half the feed per tooth. This paper presents, as a novelty, the analysis of low-frequency vibration parameters in boring processes and their effect on chip formation and internal hole roughness. This has a practical significance for the definition of a methodology based on the torque model for the selection of conditions on other hole-making processes, cutting parameters and/or materials.

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Section: Fitting Of Force Model Resultsmentioning

confidence: 99%

Section: Fitting Of Force Model Resultsmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

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Predicted Torque Model in Low-Frequency-Assisted Boring (LFAB) Operations

Veiga¹,

Val²,

Penalva³

et al. 2021

Metals

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show abstract

“…Since the 1990s, in-depth research works have been conducted on elliptical vibration cutting and designing EVC devices (Tan et al, 2018;Kim and Loh, 2007;Zhang and Song, 2019). The machinability of difficult-toprocess material was also examined in Lu et al (2017) and Dong et al (2020), and path planning was reported on in Kim and Loh (2008), Jieqiong et al (2013) and so on. However, the improvement of control accuracy in the process of 3D EVC is a challenging task, and both the dynamic and static characteristics of the system need to be tuned to obtain the optimal parameters.…”

Section: Introductionmentioning

confidence: 99%

Parameter tuning of robust adaptive fuzzy controller for 3D elliptical vibration-assisted cutting

Wang

et al. 2021

Mech. Sci.

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Abstract. Elliptical vibration cutting (EVC), as a precision machining technology, is used in many applications. In precision machining, control accuracy plays an essential role in improving the machinability of difficult-to-machine materials. To improve the control accuracy, dynamic and static characteristics of the system need to be tuned to obtain the optimal parameters. In this paper, we use a glowworm algorithm with an improved adaptive step size to tune the parameters of a robust adaptive fuzzy controller. We then obtain the optimal controller parameters through simulation. The optimal solution of the controller parameters is then applied to a 3D EVC system model for simulation and closed-loop testing experiments. The results indicate that a good agreement between the ideal curve and the tracking signal curve verifies the optimality of the controller parameters. Finally, under certain cutting conditions, the workpieces of three different materials are cut with two different cutting methods. The study revealed that the surface roughness value is reduced by 20 %–32 %, which further verifies the effectiveness of the optimal controller's parameters.

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“…Zhang et al [21] demonstrated that ultrasonic vibration-assisted boring can effectively overcome the chip block problem, reduce the aperture error and surface roughness, suppress the chatter at the same time, and thus improve the deep-hole boring machining quality. Dong et al [22] designed an ultrasonic elliptical vibration boring device for deep-hole parts, and experimentally confirmed that it can significantly reduce the boring force, surface roughness, cutting chip length, and vibration during the machining of high-strength steel 18Cr2Ni4WA. Saoubi et al [23] pointed that titanium alloy has attracted tremendous attention, and has been extensively applied for structural components in the aerospace industries.…”

Section: Introductionmentioning

confidence: 99%

Feasibility Study on Machining Super-dimensioned Aviation Deep-hole Ti6Al4V Part With Axial Ultrasonic Vibration-assisted Boring

Zhang

Wang

et al. 2021

Preprint

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Deep-holes are typical super-dimensioned parts of aircraft structures, with associated machining technology which is recognized as challenging due to the difficult-to-machine material, the narrow and enclosed machining environment, and the weak rigidity and large deformation of the boring bar. Axial ultrasonic vibration-assisted cutting has been proved to greatly enhance machining performance, especially in the precision machining of aviation alloy. This paper focuses on the machining of a super-dimensioned titanium alloy Ti6Al4V aviation deep-hole part (aspect ratio exceeding 20) with the axial ultrasonic vibration-assisted boring (AUVB) method. First, the kinetics of the AUVB process is analyzed and a retrospective of its separation cutting feature is provided. Subsequently, a multi-step cantilever beam model of the boring bar is established to analyze its static rigidity and dynamic stability. The aperture error of bored hole is deduced, and it is found to be mainly determined by the diameter of the basic hole, the cutting depth, the boring force and the length, diameter, elastic modulus, and rotational inertia of each step. Size coefficient, rather than aspect ratio, is then put forward to represent the static rigidity of the boring bar, which is proportional to the third power of the diameter and inversely proportional to the fourth power of the diameter. In addition, two different vibration cases, namely modal-coupling vibration and regenerative vibration are considered for dynamic stability analysis. The actual dynamic rigidity of AUVB in both of these cases is larger than that of conventional boring (CB), resulting from the lower actual boing force and the larger actual cutting depth. Next, the morphology of bored surface is analyzed, and the geometric height of peaks formed by AUVB and CB are calculated. Phase shift φ= π is suggested for obtaining a better surface in AUVB. Finally, the feasibility of AUVB on machining a super-dimensioned titanium alloy Ti6Al4V aviation deep-hole part with three different sizes of boring bar (size coefficients are 7473, 4076 and 2718, respectively) is verified through systematic experiments, and compared with CB. Results demonstrate that AUVB has obvious advantages in reducing the boring force, improving boring accuracy, suppressing vibration and promoting surface quality. Furthermore, the aperture error decreases to 50% and vibration amplitudes decrease to only 20%-25%. The overall surface roughness of the deep-hole part stays below Ra=0.8μm with rotational speeds of 60r/min and 80r/min, and the surface residual stress state is transferred from the tensile state to a compressive one. As a result, not only AUVB can provide better boring accuracy and surface finish, but it also can enhance the surface fatigue properties.

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Investigation on ultrasonic elliptical vibration boring of deep holes with large depth–diameter ratio for high-strength steel 18Cr2Ni4WA

Cited by 21 publications

References 31 publications

Predicted Torque Model in Low-Frequency-Assisted Boring (LFAB) Operations

Predicted Torque Model in Low-Frequency-Assisted Boring (LFAB) Operations

Parameter tuning of robust adaptive fuzzy controller for 3D elliptical vibration-assisted cutting

Feasibility Study on Machining Super-dimensioned Aviation Deep-hole Ti6Al4V Part With Axial Ultrasonic Vibration-assisted Boring

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