Modeling and experimental analysis of surface topography generation mechanism during ultrasonic vibration-assisted grinding

Yang, Zhenyu; Zou, Ping; Zhou, Liang; Wang, Xue; Usman, Mustapha Mukhtar

doi:10.1016/j.precisioneng.2022.11.017

Cited by 15 publications

(3 citation statements)

References 44 publications

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“…For many years, micromachining technology has dedicated significant efforts to investigating the microscopic scale material removal process [ 10 , 11 ]. Recently, vibration-assisted micro machining has arisen as a promising approach for accurate and flexible surface texturing [ 12 , 13 , 14 ]. Multiple advantages and improvements have been proved, such as reduced cutting forces [ 15 ], extended tool life, minimized burr formation, improved surface quality [ 16 ], and the ability to machine hardened metals and ceramics [ 17 , 18 ].…”

Section: Introductionmentioning

confidence: 99%

Theoretical and Experimental Investigation of Surface Textures in Vibration-Assisted Micro Milling

Song,

Zhang,

Jing

et al. 2024

Micromachines

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Vibration-assisted micro milling is a promising technique for fabricating engineered mi-cro-scaled surface textures. This paper presents a novel approach for theoretical modeling of three-dimensional (3D) surface textures produced by vibration-assisted micro milling. The proposed model considers the effects of tool edge geometry, minimum uncut chip thickness (MUCT), and material elastic recovery. The surface texture formation under different machining parameters is simulated and analyzed through mathematical modeling. Two typical surface morphologies can be generated: wave-type and fish scale-type textures, depending on the phase difference between tool paths. A 2-degrees-of-freedom (2-DOF) vibration stage is also developed to provide vibration along the feed and cross-feed directions during micro-milling process. Micro-milling experiments on copper were carried out to verify the ability to fabricate controlled surface textures using the vibration stage. The simulated and experimentally generated surfaces show good agreement in geometry and dimensions. This work provides an accurate analytical model for vibration-assisted micro-milling surface generation and demonstrates its feasibility for efficient, flexible texturing.

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Section: Introductionmentioning

confidence: 99%

Theoretical and Experimental Investigation of Surface Textures in Vibration-Assisted Micro Milling

Song,

Zhang,

Jing

et al. 2024

Micromachines

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“…In recent years, ultrasonic vibration-assisted grinding (UVAG) technology has been widely concerned, aiming at obtaining high surface integrity, especially for difficult-to-cut materials in aerospace industries [16]. Those researches show that the usage of ultrasonic composite technology contributes to the reduction of the grinding forces and temperature, the significantly improvement of grinding quality, and an enhancement in material removal rate during machining difficult-to-cut materials [17][18][19][20][21][22][23][24][25]. Ding et al [17] developed a radial ultrasonic vibration-assisted machining device and applied it to machining the particle-reinforcing titanium matrix composites.…”

Section: Introductionmentioning

confidence: 99%

“…They found that the employment of radial ultrasonic vibrations can significantly reduce grinding temperature, and improve the processing efficiency. Zou et al [18] simulated the grinding surface of UVAG by considering the geometric features of the actual shape and distribution of CBN particles. Their implied that experimental results were in agreement with the simulation results, and the groove-like ultrasonic vibration texture was found on the grinding surface.…”

Section: Introductionmentioning

confidence: 99%

Grindability of γ-TiAl intermetallic compounds during ultrasonic vibration-assisted high efficiency deep grinding process

Wang

Tang

Zhao

et al. 2023

Int J Adv Manuf Technol

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Gamma titanium-aluminum intermetallic compounds (γ-TiAl) have an important application significance in the field of aero-engines owing to their excellent mechanical properties (e.g., high-temperature resistance, high toughness, etc). Grinding as an important method was used to realize the high efficiency and precise machining for difficult-to-cut materials. However, the machining defects (e.g., adhesion, cracks, and even burns, etc) were confronted on machined surface of γ-TiAl materials under high grinding force and temperature loads. In this case, the new machining methods combined with the ultrasonic vibration and high-efficiency deep grinding technology was proposed to improve the machining quality and efficiency. Comparative trials of ultrasonic vibration-assisted high efficiency deep grinding (UVHEDG) and high efficiency deep grinding (HEDG) were carried out to study the grinding performance, in terms of the grinding force, grinding temperature, specific grinding energy, and machining surface quality. Results show that UVHEDG possess the lower grinding force and temperature by 38.69% and 39.05% compared with HEDG, respectively. In addition, the employment of ultrasonic vibrations contributes to maintain the abrasive sharpness, and thus the specific grinding energy is reduced by 23.95%. Ground surface roughness can be reduced by 19.53%, and the grinding surface quality is effectively improved due to the lubrication effect and track overlap effect under ultrasonic vibration.

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Effect of radial ultrasonic vibrations on wear properties of CBN grains in high-speed grinding of PTMCs

Zhao,

Wang,

Tang

et al. 2023

Int J Adv Manuf Technol

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Modeling and experimental analysis of surface topography generation mechanism during ultrasonic vibration-assisted grinding

Cited by 15 publications

References 44 publications

Theoretical and Experimental Investigation of Surface Textures in Vibration-Assisted Micro Milling

Theoretical and Experimental Investigation of Surface Textures in Vibration-Assisted Micro Milling

Grindability of γ-TiAl intermetallic compounds during ultrasonic vibration-assisted high efficiency deep grinding process

Effect of radial ultrasonic vibrations on wear properties of CBN grains in high-speed grinding of PTMCs

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