Longitudinal-torsional coupled rotary ultrasonic machining of ZrO2 ceramics: An experimental study

Chen, Fan; Bie, Wenbo; Wang, Xiaobo; Zhao, Bo

doi:10.1016/j.ceramint.2022.05.398

Cited by 20 publications

(3 citation statements)

References 27 publications

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“…The design consisted of nine distinct combinations of the selected input factor. The RUM process's effectiveness was assessed using performance metrics such as material reduction rate and surface quality [33][34][35][36].…”

Section: Experimental Designmentioning

confidence: 99%

Experimental investigation and parametric optimization of rotary ultrasonic machining of different bio-ceramic materials

Vishnoi,

Mamatha,

Singh

et al. 2024

Phys. Scr.

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Rotary ultrasonic machining (RUM) is a highly promising technique for machining bio-ceramic materials due to its ability to achieve high precision and superior surface quality. This research focuses on an experimental investigation and parametric optimization of RUM for different bio-ceramic materials, intending to optimize multiple machining responses simultaneously. The experimental setup involves utilizing a 3-axis CNC ultrasonic machine to machine three different workpieces with slot cutting. Various machining parameters, such as tool feed rate and tool rotating speed, are studied to determine their impacts. An orthogonal array design based on Taguchi optimization is used to execute the experiments effectively. Material removal rate (MRR) and surface roughness (SR) are monitored and statistically analyzed as a consequence of the responses. ANOVA demonstrates that the tool feed rate has a considerable impact on the output reactions, with material type and tool rotational speed also playing a role. For multiple response optimizations, the Taguchi-Grey method is used to achieve the best trade-off between MRR and SR. The results demonstrate that material type has the most substantial impact on surface roughness, followed by feed rate and spindle speed. In contrast, feed rate has the most significant effect on the material removal rate, followed by the material type and spindle speed. The optimal parameter settings for achieving the desired output parameter are determined. The confirmation experiments validate the effectiveness of the optimized parameters. The feed rate of 5 mm/min, and spindle speed of 2500 rpm were discovered to be the optimal condition for achieving maximum MRR and minimum Ra. The MRR and surface roughness values were measured as 1.7266 mm3/min and 1.5611 microns respectively.

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Section: Experimental Designmentioning

confidence: 99%

Experimental investigation and parametric optimization of rotary ultrasonic machining of different bio-ceramic materials

Vishnoi,

Mamatha,

Singh

et al. 2024

Phys. Scr.

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“…Ultrasonic machining removes materials by means of ultrasonic frequency tools with small amplitude vibration in the abrasive liquid medium or dry abrasive, abrasive impact, polishing, and cavitation [92,93]. Along a certain direction of the tool or workpiece is subjected to ultrasonic vibration to carry out vibration machining, the workpiece surface materials to be processed mainly under the action of mechanical impact peeling, accompanied by polishing and super cavitation finally realize the forming process [94,95]. The workpiece is bonded to each other by ultrasonic vibration.…”

Section: Special Energy Field Machining Technologymentioning

confidence: 99%

A Review of Advances in Fabrication Methods and Assistive Technologies of Micro-Structured Surfaces

Zhang

Cao

et al. 2023

Processes

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Micro-structured surfaces possess excellent properties of friction, lubrication, drag reduction, antibacterial, and self-cleaning, which have been widely applied in optical, medical, national defense, aerospace fields, etc. Therefore, it is requisite to study the fabrication methods of micro-structures to improve the accuracy and enhance the performance of micro-structures. At present, there are plenty of studies focusing on the preparation of micro-structures; therefore, systematic review of the technologies and developing trend on the fabrication of micro-structures are needed. In present review, the fabrication methods of various micro-structures are compared and summarized. Specially, the characteristics and applications of ultra-precision machining (UPM) technology in the fabrication of micro-structures are mainly discussed. Additionally, the assistive technologies applied into UPM, such as fast tool servo (FTS) technology and slow tool servo (STS) technology to fabricate micro-structures with different characteristics are summarized. Finally, the principal characteristics and applications of fly cutting technology in manufacturing special micro-structures are presented. From the review, it is found that by combining different machining methods to prepare the base layer surface first and then fabricate the sublayer surface, the advantages of different machining technologies can be greatly exerted, which is of great significance for the preparation of multi-layer and multi-scale micro-structures. Furthermore, the combination of ultra-precision fly cutting and FTS/STS possess advantages in realizing complex micro-structures with high aspect ratio and high resolution. However, residual tool marks and material recovery are still the key factors affecting the form accuracy of machined micro-structures. This review provides advances in fabrication methods and assistive technologies of micro-structured surfaces, which serves as the guidance for both fabrication and application of multi-layer and multi-scale micro-structures.

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“…The development of RUM machine tools also gradually tends to high speed, multiple axes, and systematization, improving the machining accuracy and efficiency and overcoming the problems of excessive cutting forces, severe tool wear, and the surface loss of workpiece materials triggered by traditional machining. Much of the research has confirmed that spindle speed is one of the critical factors affecting the accuracy of the RUM of hard and brittle materials [ 23 , 24 , 25 , 26 , 27 , 28 , 29 ]. If the spindle speed can effectively increase, it will improve RUM’s processing quality and efficiency for hard and brittle material microstructure.…”

Section: Introductionmentioning

confidence: 99%

Design of a High-Speed Rotary Ultrasonic Machining Machine Tool for Machining Microstructure of Brittle Materials

Zhang,

Gong,

Lian

et al. 2023

Micromachines

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Aiming at the problems of low machining accuracy and more serious tool wear in the traditional diamond grinding machining (DGM) microstructure of hard and brittle materials, this paper proposes high-speed rotary ultrasonic machining (HRUM) technology and develops a HRUM machine tool. The hardware part of the machine tool mainly includes the spindle module, micro-motion system module, ultrasonic machining tank module, and data acquisition (DAQ) system module. The LabView-based controlled machining control system, including motion selection, initialization, coarse tool setting, constant force tool setting, control machining, and coordinate display module, is developed. Comparative experimental research of the HRUM and DGM of small holes in Al2O3 ceramics is carried out in the developed HRUM machine tool. The results demonstrate that HRUM effectively reduces axial cutting forces, reduces binder adhesion, and suppresses slippage while improving tool-cutting ability and extending tool life compared to DGM under the same machining parameters. This technology has essential research significance for the high-precision and efficient machining of microstructures in hard and brittle materials.

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Longitudinal-torsional coupled rotary ultrasonic machining of ZrO2 ceramics: An experimental study

Cited by 20 publications

References 27 publications

Experimental investigation and parametric optimization of rotary ultrasonic machining of different bio-ceramic materials

Experimental investigation and parametric optimization of rotary ultrasonic machining of different bio-ceramic materials

A Review of Advances in Fabrication Methods and Assistive Technologies of Micro-Structured Surfaces

Design of a High-Speed Rotary Ultrasonic Machining Machine Tool for Machining Microstructure of Brittle Materials

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