Ultrasonic-assisted electrochemical drill-grinding of small holes with high-quality

Zhu, Xiangwei; Liu, Yong; Zhang, Jianhua; Wang, Kan; Kong, Huanghai

doi:10.1016/j.jare.2020.02.010

Cited by 35 publications

(10 citation statements)

References 27 publications

Supporting

Mentioning

Contrasting

Order By: Relevance

“…The parameters of the SiCp/Al Johnson-Cook model are shown in Table 1. Variables ε* and T* can be obtained by Equations ( 27) and ( 28) [28,31,32]:…”

Section: Prediction Of Friction Component At Tmi (F M )mentioning

confidence: 99%

Cutting Force Prediction Model for Elliptical Vibration Cutting SiCp/Al Based on Three-Phase Friction Theory

Liu

Zhang

Wang³

2021

Applied Sciences

View full text Add to dashboard Cite

The friction behavior in the tool-chip interface is an essential issue in aluminum matrix composite material (AMCM) turning operations. Compared with conventional cutting, the elliptical vibration (EVC) cutting AMCM has attractive advantages, such as low friction, small cutting forces, etc. However, the friction mechanism of the EVC cutting AMCM is still inadequate, especially the model for cutting forces analyzing and predicting, which hinders the application of EVC in the processing of AMCM. In this paper, a cutting force prediction model for EVC cutting SiCp/Al is established, which is based on the three-phase friction (TPF) theory. The friction components are evaluated and predicted at the tool-chip interface (TCI), tool-particle interface (TPI) and tool-matrix (TMI), respectively. In addition, the tool-chip contact length and SiC particle volume fraction were defined strictly and the coefficient of friction was predicted. Based on the Johnson-Cook constitutive model, the experiment was conducted on SiCp/Al. The cutting speed and tool-chip contact length were used as input parameters of the friction model, and the dynamic changes of cutting force and stress distribution were analyzed. The results shown that when cutting speed reaches 574 m/min, the tool-chip contact length decreases to 0.378 mm. When the cutting speed exceeds 658 m/min, the cutting force decreases to a minimum of 214.9 N and remains stable. In addition, compared with conventional cutting, the proposed prediction model can effectively reduce the cutting force.

show abstract

“…The parameters of the SiCp/Al Johnson-Cook model are shown in Table 1. Variables ε* and T* can be obtained by Equations ( 27) and ( 28) [28,31,32]:…”

Section: Prediction Of Friction Component At Tmi (F M )mentioning

confidence: 99%

Cutting Force Prediction Model for Elliptical Vibration Cutting SiCp/Al Based on Three-Phase Friction Theory

Liu

Zhang

Wang³

2021

Applied Sciences

View full text Add to dashboard Cite

show abstract

“…Yin et al [26]discovered a new method for measuring wheel wear and predicting the surface roughness. Zhu et al [27]analysed the electrochemical drilling and grinding process and conducted a simulation study to elucidate the role of the ultrasonicassisted electrochemical drill-grinding (UAECDG) process in improving the machining accuracy. Zhou et al [28] found that applying axial vibration increased the number of dynamically active grains, produced a uniform undeformed chip thickness, and reduced the surface roughness.…”

Section: Introductionmentioning

confidence: 99%

Surface topography modeling and analysis of camshaft generated by swing grinding process

Zhou

et al. 2022

Int J Adv Manuf Technol

View full text Add to dashboard Cite

In conventional grinding (CG), camshafts with wide profiles suffer from poor quality and low efficiency because the large contact area between the grinding wheel and camshaft profile limits the diffusion of grinding temperature, leading to burn defects. Swing grinding (SG) can mitigate these problems as it involves a reciprocating motion along the axis of the grinding wheel; however, the lack of understanding of machined surface topography has restricted its application. Therefore, in this study, a surface topography prediction model was proposed based on the distribution, shape, and trajectory of grains. The model was verified through experiments, and the mean error was 10.2% for Rax and 3.8% for Ray; the roughness along the grinding direction was Rax, and the roughness along the vertical grinding direction was Ray. Compared to CG, SG has a 8% lower Rax. The influence of the wheel speed and feed rate in SG is consistent with that in CG. Rax exhibited a periodic trend with an increase in the swing amplitude and a monotonically decreasing trend with an increase in the swing frequency. The variation trend of Ray with the swing amplitude was the same as that of Rax. Furthermore, Ray exhibited a nonlinear increasing trend with an increase in swing frequency. Considering the processing and practical application of camshafts, the swing amplitude should be within 4 mm, the swing frequency should be within 3 Hz, the grinding wheel speed should be large, and the feed rate should be small.

show abstract

“…This technique enhanced part quality by reducing the surface roughness parameter (Ra) from 2.5 to 1 µm and the taper angle of the drilled holes from 11 • to 1 • . In addition, Zhu et al [17] applied ultrasonic vibration to electrochemical drill-grinding and machined micro-holes with a surface roughness of 0.31 µm and a taper of less than 0.6 • . All above investigations confirmed the beneficial effect of ultrasonics on ECM.…”

Section: Introductionmentioning

confidence: 99%

Ultrasound-Assisted Through-Mask Electrochemical Machining of Hole Arrays in ODS Superalloy

Wang

Zhang

et al. 2020

Materials

View full text Add to dashboard Cite

Micro-hole arrays have found wide applications in aerospace, precision instruments, and biomedicine. Among various methods of their production, including mechanical, laser, and electrical discharge, electrochemical machining (ECM) is considered the most lucrative due to its wide processing range, high surface quality, and excellent productivity. In particular, ultrasound-assisted through-mask ECM exhibits an enhanced machining precision due to ultrasonic cavitation, which promotes the removal of the electrolytic products and bubbles. In this study, the equation of cavitation bubble oscillation was derived and numerically solved to study the influence of six different parameters on the ultrasonic cavitation and electrolysis process, and their optimal values were determined. The feasibility of the proposed ultrasound-assisted through-mask ECM technology with the optimized parameters was experimentally corroborated by the fabrication of a high-quality hole array in an oxide dispersion strengthened (ODS) MA956 superalloy.

show abstract

Ultrasonic-assisted electrochemical drill-grinding of small holes with high-quality

Cited by 35 publications

References 27 publications

Cutting Force Prediction Model for Elliptical Vibration Cutting SiCp/Al Based on Three-Phase Friction Theory

Cutting Force Prediction Model for Elliptical Vibration Cutting SiCp/Al Based on Three-Phase Friction Theory

Surface topography modeling and analysis of camshaft generated by swing grinding process

Ultrasound-Assisted Through-Mask Electrochemical Machining of Hole Arrays in ODS Superalloy

Contact Info

Product

Resources

About