The mechanism of material removal in ultrasonic drilling of engineering ceramics

Zhang, Q H; Wu, Changliang; Sun, Jin-Zhao; Jia, Zhixu

doi:10.1243/0954405001517874

Cited by 39 publications

(20 citation statements)

References 9 publications

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“…2. Many abrasive machining models [17][18][19][20][21][22][23][24] began with an analysis of one abrasive particle. The models were then derived by summing up the effects of all active abrasive particles taking part in cutting.…”

Section: Approach To Model Developmentmentioning

confidence: 99%

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A cutting force model for rotary ultrasonic machining of brittle materials

Liu

Cong

Pei

et al. 2012

International Journal of Machine Tools and Manufacture

189

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Knowing cutting force in rotary ultrasonic machining (RUM) can help optimizing input variables. RUM of brittle materials has been investigated both experimentally and theoretically. However, there are no reports on cutting force models for RUM of brittle materials. This paper presents a mechanistic model for cutting force in RUM of brittle materials. Assuming that brittle fracture is the primary mechanism of material removal in RUM of brittle materials, the cutting force model is developed step by step. On the basis of this mechanistic model, relationships between cutting force and input variables (such as spindle speed, feed rate, ultrasonic vibration amplitude, abrasive size, and abrasive concentration) are predicted.

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Section: Approach To Model Developmentmentioning

confidence: 99%

“…Material removal mechanism in RUM of brittle materials has been mainly attributed to brittle fracture in the literature [14,[17][18][19][23][24]. The brittle fracture mechanism of materials has been discussed using indentation fracture mechanics [25][26][27][28].…”

Section: Volume Of Materials Removed By One Abrasive Particlementioning

confidence: 99%

A cutting force model for rotary ultrasonic machining of brittle materials

Liu

Cong

Pei

et al. 2012

International Journal of Machine Tools and Manufacture

189

View full text Add to dashboard Cite

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“…drilling, grinding and electric discharge machining), rotary 1 ultrasonic machining (RUM) is an alternative machining method which is of particular interest for the machining of brittle and nonconductive materials as demonstrated in previous studies. 3,4 RUM is a hybrid machining process based on the combined material removal mechanisms of diamond grinding and ultrasonic machining resulting in higher material removal rates. The ultrasonically vibrating diamond-bonded tool is axially fed into the workpiece at a constant feed rate.…”

Section: Introductionmentioning

confidence: 99%

A study on the effect of main process parameters of rotary ultrasonic machining for drilling BK7 glass

Anwar

Nasr

Pervaiz

et al. 2018

Advances in Mechanical Engineering

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BK7 glass is an important engineering material with extensive applications in high-quality and precision transmissive optical components. However, BK7 glass is considered to be a difficult-to-cut material due to its high brittleness and nonconductivity. This article presents the use of rotary ultrasonic machining process for drilling holes in BK7 glass. No previous reports have been found in the literature to experimentally investigate the response of the BK7 glass to rotary ultrasonic drilling. The experimental investigations take into account the effect of the key rotary ultrasonic machining input parameters including the ultrasonic power, spindle speed and feed rate on the output responses of cutting force, exit chipping, surface roughness, hole cylindricity and overcut errors, and surface integrity. The results show that the input parameters within the current ranges can significantly affect the quality of the drilled holes. Moreover, the selected level of any input parameter has the ability to significantly affect the influence of the other input parameters on the output responses. Through proper selection of input parameters, holes could be drilled in BK7 glass with less fractured topography, low surface roughness (1.32 mm), low exit chipping size (0.85), and very low cylindricity (3 mm) and overcut (73.6 mm) errors.

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“…Pei et al [8] used rotary ultrasonic face machining first time and found the influence of the cutting depth, feed rate, and cutting tool on the machined surface quality and MRR. Zhang et al [9] established the material removal model based on the indentation theory for advanced ceramic and obtained the theoretical expression of MRR. This research verified the influence of static pressure, amplitude, spindle speed, and the grit size on MRR through experiments.…”

Section: Introductionmentioning

confidence: 99%

“…In previous study and literature review [1][2][3][4][5][6][7][8][9][10][11][12][13][14][15][16][17], it is found that there was main focus on machining ceramics and its related composite materials. The research work on rotary ultrasonic drilling of CFRP materials is rare especially on CFRP-T700.…”

Section: Introductionmentioning

confidence: 99%

Development of a cutting force prediction model based on brittle fracture for carbon fiber reinforced polymers for rotary ultrasonic drilling

Yuan

Zhang

Amin

et al. 2015

Int J Adv Manuf Technol

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Carbon fiber reinforced polymers (CFRP) T700 have got increasing demand in the aerospace industry due to their high specific strength, specific stiffness, and other unique properties. Due to their inhomogeneous, anisotropic, and thermal properties, it is challenging to achieve desired accuracy and to avoid from delamination, chip-off, cracking, and burning especially in the drilling process. The cutting force is the critical parameter which is required to minimize in order to drill a hole with better accuracy and minimize defects. In this research, the brittle fracture approach was adopted and a cutting force model was developed for CFRP-T700 based on the rotary ultrasonic drilling (RUD) process. The experimental RUD was carried out on CFRP-T700 material and found that the feed rate and spindle speed are two main parameters that affect the cutting force in RUD. The cutting force data obtained from the model and experimental setup were then analyzed and found that there is small variation even below 10 % (max value of variation is 8.5 % and the average value is 0.49 %) between simulated and measured values. So, the developed cutting force model was validated and found robust. Also, it was found that with four times increase of feed rate, there is also an increase of material removal rate (MRR) four times with the decrease in the cutting force. Moreover, this model will be much helpful to keep cutting force within limits through the optimal set of parameters as feed rate and spindle speed without extensive experimentation of such costly materials.

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The mechanism of material removal in ultrasonic drilling of engineering ceramics

Cited by 39 publications

References 9 publications

A cutting force model for rotary ultrasonic machining of brittle materials

A cutting force model for rotary ultrasonic machining of brittle materials

A study on the effect of main process parameters of rotary ultrasonic machining for drilling BK7 glass

Development of a cutting force prediction model based on brittle fracture for carbon fiber reinforced polymers for rotary ultrasonic drilling

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