Mechanism modelling and validation of ultrasonic vibration-assisted laser processing on metal surfaces

Wang, Yan; Zhang, Mingyue; Dong, Yinghuai; Zhao, Jingnan; Zhu, Xusheng; Li, Yuehua; Wen, Diyun

doi:10.1016/j.ultras.2022.106886

Cited by 10 publications

(2 citation statements)

References 24 publications

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“…The precise control of cutting conditions, such as the frequency, amplitude and direction of ultrasonic vibrations, is of crucial importance in the processing process [8]. This control capability makes it possible to effectively regulate the interaction between the tool and the workpiece, thus leading to a better machinability of the material [9][10][11]. In this context, many researchers have opted for the RUM technology for materials machining.…”

Section: Introductionmentioning

confidence: 99%

Enhancing the Machining Performance of Nomex Honeycomb Composites Using Rotary Ultrasonic Machining: A Finite Element Analysis Approach

Zarrouk,

Salhi,

Nouari

et al. 2024

Materials

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Nomex honeycomb composites (NHCs) are commonly used in various industrial sectors such as aerospace and automotive sectors due to their excellent material properties. However, when machining this type of structure, problems can arise due to significant cutting forces and unwanted cell vibrations. In order to remedy these shortcomings, this study proposes to integrate RUM (rotary ultrasonic machining) technology, which consists of applying ultrasonic vibrations along the axis of rotation of the cutter. To fully understand the milling process by ultrasonic vibrations of the NHC structure, a 3D numerical finite element model is developed using Abaqus/Explicit software. The results of the comparative analysis between the components of the simulated cutting forces and those from the experiment indicate a close agreement between the developed model and the experimental results. Based on the developed numerical model, this study comprehensively analyzes the influence of the ultrasonic vibration amplitude on various aspects, such as stress distribution in the cutting zone, chip size, the quality of the machined surface and the components of the cutting force. Ultimately, the results demonstrate that the application of ultrasonic vibrations leads to a reduction of up to 50% in the components of the cutting force, as well as an improvement in the quality of the machined surface and a reduction in the size of chips.

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Section: Introductionmentioning

confidence: 99%

Enhancing the Machining Performance of Nomex Honeycomb Composites Using Rotary Ultrasonic Machining: A Finite Element Analysis Approach

Zarrouk,

Salhi,

Nouari

et al. 2024

Materials

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show abstract

“…In another study, Kim et al analyzed tool wear and developed a numerical model to predict the machining stresses and machining temperature [26]. Wang et al modelled the ultrasonic vibration assisted laser processing on the aluminium surface and validate with the experiments to analyze the surface microstructure [27]. Dominguez-Caballero et al explored machining forces, machining temperature, and surface roughness during the simultaneous application of ultrasonic vibration and laser energies in the turning process for Ti6Al4V alloy.…”

Section: Introductionmentioning

confidence: 99%

Radial direction ultrasonic-vibration and laser assisted turning of Al3003 alloy

Deswal

Kant

2023

Mater. Res. Express

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The utilization of various energy sources to assist the machining process has become prominent to achieve substantial improvement in machining performance. These energy sources have also resulted in an alternative to cutting fluids which is safer for both the universe and human beings. The combined action of laser and ultrasonic vibration energies during the turning process has shown significant achievement in machining process capabilities. Therefore, an attempt has been made to provide ultrasonic vibration in the radial direction and laser to preheat aluminium 3003 alloy simultaneously during the ultrasonic-vibration-laser assisted turning (UVLAT) process. Machining performance has been analyzed in terms of machining forces, machining temperature, chip morphology, surface damage, and surface roughness. A comparative machining performance analysis has been carried out among the conventional turning (CT), laser assisted turning (LAT), ultrasonic vibration assisted turning (UVAT), and UVLAT processes. The outcomes of the current study indicate significant benefits of the UVLAT process on the machining performance of aluminium 3003 alloy. However, surface damage and surface roughness have been affected negatively during the UVLAT process due to the pin-point hammering and particle adhesion on the workpiece part. Hence, the selection of vibration direction is a critical factor during the vibration machining processes.

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Effect of Compressed Air Cooling on Tool Wear During Ultrasonic-Vibration-Laser Assisted Turning of Aluminium Alloy

Deswal,

Kant

2023

J. Vib. Eng. Technol.

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Mechanism modelling and validation of ultrasonic vibration-assisted laser processing on metal surfaces

Cited by 10 publications

References 24 publications

Enhancing the Machining Performance of Nomex Honeycomb Composites Using Rotary Ultrasonic Machining: A Finite Element Analysis Approach

Enhancing the Machining Performance of Nomex Honeycomb Composites Using Rotary Ultrasonic Machining: A Finite Element Analysis Approach

Radial direction ultrasonic-vibration and laser assisted turning of Al3003 alloy

Effect of Compressed Air Cooling on Tool Wear During Ultrasonic-Vibration-Laser Assisted Turning of Aluminium Alloy

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