Research on three-dimensional ultrasonic vibration-assisted turning cutting force

Duan, Jingwei; Zou, Ping; Wang, Anqi; Wei, Shiyu; Fang, Ruiming

doi:10.1016/j.jmapro.2023.02.025

Cited by 10 publications

(6 citation statements)

References 49 publications

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“…On the contrary, if the method of variable angle is used, that is, the smaller angle is used first, it can effectively reduce the cutting force of the disc cutter when cutting NHCs. Combining the results of the experiments and theoretical analysis, it was shown that these experimental results were consistent with the trend of the relationship between the angle and force obtained in Equations ( 18)- (23), indicating that the method of ultrasonic vibration machining with variable angle of the disc cutter which firstly applies a smaller angle of the tool can effectively reduce cutting forces compared to directly using a larger fixed tool angle.…”

Section: Group Processing Methodssupporting

confidence: 71%

“…Based on the above results, it can be concluded that ultrasonic vibration machining with a variable angle of the down milling disc cutter can effectively reduce cutting forces. In Equations ( 18)- (23), it was clearly illustrated that the swing angle is one of the most important factors that influence the value of cutting force. Specifically, if a larger angle is used, a larger angle will cause the increase of the force F xv and F zv .…”

Section: Group Processing Methodsmentioning

confidence: 99%

“…In comparison to traditional machining, ultrasonic vibration machining can effectively reduce cutting forces because of its intermittent cutting [ 22 , 23 ]. And many researchers have verified the effectiveness of ultrasonic vibration machining by experimental and theoretical methods.…”

Section: Introductionmentioning

confidence: 99%

See 2 more Smart Citations

Enabling Thin-Edged Part Machining of Nomex Honeycomb Composites via Optimizing Variable Angle of Disc Cutters

et al. 2023

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Machining Nomex honeycomb composites (NHCs), which are widely-used materials in the aerospace industry, is an imperative process to obtain desired profiles. However, when machining NHCs to obtain a thin-edged surface, some problems can arise due to large cutting forces. To avoid these defects, a method of ultrasonic vibration machining with variable angles of the down milling disc cutter was proposed in this study. The processing principles and motion characteristics of this method were elaborated. A theoretical model of its cutting process was established. The principle of cutting force reduction was qualitatively analyzed based on the model, and an experimental validation was conducted. The results demonstrated that, due to a smaller swing angle in each pass, the proposed method could reduce the fractal dimension of the machined surface by 6.01% compared to 1° with 10° of angle in each pass. And severe machining defects were decreased. Additionally, comparing the process of the fixed 10° angle of ultrasonic vibration machining with the process of a 1° angle in a pass, cutting force can be significantly reduced by 33.5%, demonstrating the effectiveness of the proposed method which improved surface quality by reducing cutting forces.

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Section: Group Processing Methodssupporting

confidence: 71%

Section: Group Processing Methodsmentioning

confidence: 99%

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Enabling Thin-Edged Part Machining of Nomex Honeycomb Composites via Optimizing Variable Angle of Disc Cutters

et al. 2023

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“…By optimizing the process parameters, a regular micro-texture morphology was manufactured, which exhibited a good friction performance. To explore the variations in cutting force during material removal, Duan et al [59] developed a cutting force simulation model that considered the effects of vibration amplitude and other cutting parameters on cutting force.…”

Section: Ultrasonic Vibration-assisted Turningmentioning

confidence: 99%

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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“…This phenomenon's versatility is demonstrated across a range of materials including austenitic stainless steel, Inconel 718, and 7075-T651 aluminium alloy, where the meticulous assessment of parameters elucidates their influence on cutting performance and force reduction. [5][6][7][8][9] The longevity of cutting tools is notably extended through ultrasonic turning, which harnesses vibrational energy to control heat generation and diminish tool-chip adhesion. The cumulative result is increased durability and a reduction in the frequency of tool replacements.…”

Section: Introductionmentioning

confidence: 99%

Investigation of surface topography in ultrasonic-assisted turning of C45 carbon steel

Bui,

Nguyen,

Kien Le

et al. 2023

Jpn. J. Appl. Phys.

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This study compares ultrasonic-assisted turning to conventional turning in terms of their effects on surface texture and cutting forces during the machining of C45 carbon steel. Experiments were conducted on a lathe equipped with a 1000 W ultrasonic generator running at 20 kHz. Ultrasonic-assisted turning results in small, evenly distributed spherical scratches on the workpiece, while conventional turning leads to long, uneven cutting marks. Significantly, ultrasonic-assisted turning achieves a notably smoother surface finish than conventional turning. As the depth of cut increases, conventional turning causes increasingly uneven surface topography, whereas ultrasonic-assisted turning maintains surface stability and uniformity. Moreover, cutting forces see a substantial rise of approximately 40% with conventional turning as the depth of cut increases. In contrast, ultrasonic-assisted turning witnesses a marginal force increase of about 15.84%.

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Research on three-dimensional ultrasonic vibration-assisted turning cutting force

Cited by 10 publications

References 49 publications

Enabling Thin-Edged Part Machining of Nomex Honeycomb Composites via Optimizing Variable Angle of Disc Cutters

Enabling Thin-Edged Part Machining of Nomex Honeycomb Composites via Optimizing Variable Angle of Disc Cutters

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

Investigation of surface topography in ultrasonic-assisted turning of C45 carbon steel

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