Rotary ultrasonic elliptical machining for side milling of CFRP: Tool performance and surface integrity

Geng, Daxi; Zhang, Deyuan; Xu, Yonggang; He, Fuchu; Liu, Dapeng; Duan, Zuoheng

doi:10.1016/j.ultras.2015.02.006

Cited by 88 publications

(19 citation statements)

References 21 publications

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“…It was found that tool wear with ultrasonic vibration was less than in conventional milling due to the axial movement of the cutter which periodically increases the gap between the tool and the workpiece which promotes interfacial lubrication. This is similar to the findings of Manjot et al [14] and Geng et al [15]. The conclusion is that tools used in ultrasonicassisted machining last longer.…”

Section: Resultssupporting

confidence: 91%

The Machining of Hard Mold Steel by Ultrasonic Assisted End Milling

Tsai

Chang

2016

Applied Sciences

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Abstract:This study describes the use of ultrasonic-assisted end milling to improve the quality of the machined surface of hard Stavax (modified AISI 420) mold steel and to reduce the amount of work involved in the final polishing process. The effects of input voltage, the stretch length and cutter holding force on the amplitude of the ultrasonic vibration used were measured. The effect of ultrasonic frequency (25 and 50 kHz) and amplitude (0, 2.20 and 3.68 µm) as well as the effect of the rake angle (6 • and −6 • ) and the cutter helix angle (25 • , 35 • and 45 • ) on tool wear and quality of the workpiece surface finish were also investigated. It was found that the ultrasonic amplitude increased with cutter stretch length and input voltage, as expected. The amplitude remained constant when the cutter holding force exceeded 15 N. The experimental results showed that the ultrasonic amplitude had an optimum value with respect to surface finish. However, large amplitude ultrasonics did not necessarily improve quality. Furthermore, the cutters used for ultrasonic-assisted milling show less wear than those used for normal milling. It was also found that a positive rake angle and cutters with a large helix angle gave a better surface finish.

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Section: Resultssupporting

confidence: 91%

The Machining of Hard Mold Steel by Ultrasonic Assisted End Milling

Tsai

Chang

2016

Applied Sciences

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“…In early studies, VAM was used for traditional macro-scale metal-cutting applications [ 15 ]. In recent years, VAM systems have been applied in turning [ 16 , 17 , 18 , 19 ], milling [ 20 , 21 , 22 , 23 , 24 ], drilling [ 25 , 26 , 27 ] or grinding [ 28 , 29 , 30 , 31 , 32 , 33 ] and so on. In such research, VAM technique has advantage of the reducing cutting force and prolonging tool lifespan [ 34 , 35 , 36 , 37 ].…”

Section: Introductionmentioning

confidence: 99%

Experimental Study on the Performance of Hydraulic Vibration Assisted Broaching (HVAB) Based on Piezoelectric Sensors

Meng

Shi

et al. 2018

Sensors

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In order to improve the keyway broaching process and verify the feasibility of vibration-assisted broaching process, an experimental study on a novel hydraulic vibration assisted broaching (HVAB) system with double-valve electro-hydraulic exciter (DVEHE) is proposed in this paper. The performances of HVAB at different excitation frequencies were compared from three aspects: (a) the cutting force under the different vibration frequencies, (b) the surface roughness of the workpiece, and (c) the flank face wear of the tool. For precision on-line measurement of larger broaching forces, four piezoelectric sensors were fixed on the broaching machine. The experimental results show that HVAB can effectively improve the performance of the broaching process, approximately reduce the broaching force by as much as 9.7% compared to conventional broaching (CB) and improve the surface quality of workpiece. Some explanations are offered to support the observations.

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“…The burr direction generally follows the fiber direction. (2) Surface fiber tear: During milling, in the inverse fiber direction, the surface carbon fiber is bent and broken by the tool, and the broken crack stretches deep into the material of the surface layer of the workpiece, and a tear defect is formed [15][16][17][18]. If the residual burr is extremely long, it can easily be twined by the cutter tooth and break the fiber.…”

Section: Introductionmentioning

confidence: 99%

Surface Quality of Staggered PCD End Mill in Milling of Carbon Fiber Reinforced Plastics

et al. 2017

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Machined surface quality determines the reliability, wear resistance and service life of carbon fiber reinforced plastic (CFRP) workpieces. In this work, the formation mechanism of the surface topography and the machining defects of CFRPs are proposed, and the influence of milling parameters and fiber cutting angles on the surface quality of CFRPs is obtained, which can provide a reference for extended tool life and good surface quality. Trimming and slot milling tests of unidirectional CFRP laminates are performed. The surface roughness of the machined surface is measured, and the influence of milling parameters on the surface roughness is analyzed. A regression model for the surface roughness of CFRP milling is established. A significance test of the regression model is conducted. The machined surface topography of milling CFRP unidirectional laminates with different fiber orientations is analyzed, and the effect of fiber cutting angle on the surface topography of the machined surface is presented by using a digital super depth-of-field microscope and scanning electron microscope (SEM). To study the influence of fiber cutting angle on machining defects, the machined topography under different fiber orientations is analyzed. The slot milling defects and their formation mechanism under different fiber cutting angles are investigated.

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Rotary ultrasonic elliptical machining for side milling of CFRP: Tool performance and surface integrity

Cited by 88 publications

References 21 publications

The Machining of Hard Mold Steel by Ultrasonic Assisted End Milling

The Machining of Hard Mold Steel by Ultrasonic Assisted End Milling

Experimental Study on the Performance of Hydraulic Vibration Assisted Broaching (HVAB) Based on Piezoelectric Sensors

Surface Quality of Staggered PCD End Mill in Milling of Carbon Fiber Reinforced Plastics

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