Ultrasonic cavitation and vibration hybrid-assisted micro-drilling of stainless steel

Liang, Zhiqiang; Ma, Yue; Qianqian, Nie; Wang, Xibin; Zhou, Tianfeng; Guo, Haixin; Sun, Xiaofei; Jiang, Likun

doi:10.1007/s00170-019-04247-3

Cited by 13 publications

(3 citation statements)

References 20 publications

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“…As a special processing technology, ultrasonic assisted machining has developed rapidly in recent years and has been gradually promoted to various fields of mechanical processing, forming a series of ultrasonic machining technologies such as ultrasonic assisted drilling, ultrasonic assisted grinding and polishing, ultrasonic assisted rolling, and shot peening [9][10][11][12][13]. Ultrasonic machining technology was introduced into hard and brittle materials grinding processing, and the quality and efficiency of grinding could be effectively improved by using ultrasonic highfrequency vibration impact and ultrasonic cavitation [14,15]. Xu W et al used ultrasonic bending vibration to assist the chemical mechanical polishing of sapphire substrates, and the results showed that ultrasonic vibration assisted chemical mechanical polishing can greatly reduce the surface roughness compared with traditional chemical mechanical polishing [16].…”

Section: Introductionmentioning

confidence: 99%

Mechanism and Experiment Study of Non-Contact Ultrasonic Assisted Grinding

Huang

Zhong

et al. 2021

Actuators

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Ultrasonic-assisted grinding processing can effectively reduce the surface roughness and enhance the processing efficiency in the processing of hard and brittle materials. However, the most common ultrasonic assisted grinding is a type of contact ultrasonic grinding where the grinding tool directly contacts the workpiece, which means that it is necessary to accurately control the pre-pressure of the grinding tool on the workpiece. The control of pre-pressure will inevitably increase the complexity of the grinding device, and it is easy to wear the workpiece because of improper pre-pressure control. In this paper, a non-contact ultrasonic grinding method is proposed and the machining mechanism of non-contact ultrasonic grinding is revealed. The resonant frequency of the ultrasonic vibration system and vibration amplitude of the grinding tool working face were simulated and experimentally tested, respectively. Then, the experiment of non-contact ultrasonic grinding of a sapphire wafer was carried out. The result showed that non-contact ultrasonic grinding of the sapphire wafer could reduce the surface roughness by 48.6%. Compared with traditional contact grinding of sapphire wafer under certain pre-pressure conditions, the experimental results show that non-contact ultrasonic grinding has better effects in reducing surface roughness, improving processing efficiency, and improving the quality uniformity of the workpiece machining surface.

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Section: Introductionmentioning

confidence: 99%

Mechanism and Experiment Study of Non-Contact Ultrasonic Assisted Grinding

Huang

Zhong

et al. 2021

Actuators

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“…Liew et al [ 15 ] adopted ultrasonic cavitation-assisted micro-EDM in micro-holes and found that the oscillation of cavitation bubble group could significantly improve the discharge rate of debris, and decline the debris adhesion. Liang et al [ 16 ] investigated the effect of ultrasonic cavitation on the micro drilling stainless steel and reported that it substantially improved the adhesion and winding of cuttings to the tool and enhanced the quality and accuracy of micro-holes. Toh [ 17 ] studied the ultrasonic cavitation effect on the milling stainless steel and concluded that it could effectively decrease the burr height.…”

Section: Introductionmentioning

confidence: 99%

Cavitation Effect in Ultrasonic-Assisted Electrolytic In-Process Dressing Grinding of Nanocomposite Ceramics

Chen

Bie

et al. 2021

Materials

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Ultrasonic-assisted electrolytic in-process dressing (UA-ELID) grinding is a promising technology that uses a metal-bonded diamond grinding wheel to achieve a mirror surface finish on hard and brittle materials. In this paper, the UA-ELID grinding was applied to nanocomposite ceramic for investigating the cavitation effect on the processing performance. Firstly, the ultrasonic cavitation theory was utilized to define the cavitation threshold, collapse of cavitation bubbles, and variation of their radii. Next, the online monitoring system was designed to observe the ultrasonic cavitation under different ultrasonic amplitude for the actual UA-ELID grinding test. A strong effect of ultrasonic cavitation on the grinding wheel surface and the formed oxide film was experimentally proved. Besides, under the action of ultrasonic vibration, the dressing effect of the grinding wheel was improved, and the sharpness of grain increased by 43.2%, and the grain distribution was dramatically changed with the increase of ultrasonic amplitude. Compared with the conventional ELID (C-ELID) grinding, the average protrusion height increased by 14.2%, while the average grain spacing dropped by 21.2%. The UA-ELID grinding reduced the workpiece surface roughness Rz and Ra by 54.2% and 46.5%, respectively, and increased the surface residual compressive stress by 44.5%. The surface morphology observation revealed a change in the material removal mechanism and improvement of the surface quality by ultrasonic cavitation effect. These findings are considered instrumental in theoretical and experimental substantiation of the optimal UA-ELID grinding parameters for the processing of nanocomposite ceramics.

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“…Ohashi et al [13] studied the application of cavitation in precision abrasive machining and concluded that better machining effect can be obtained by using cavitation and the fine surface can be easily processed with simple equipment. Liang et al [14] applied ultrasonic cavitation to ultrasonic vibration drilling of stainless steel micropores and pointed out that this method can effectively improve chip breaking ability greatly reduce thrust prolong tool life and obtain the best micro hole machining quality. Toh [15] proposed the concept of ultrasonic cavitation peening and used ultrasonic cavitation to improve the surface properties of materials.…”

mentioning

confidence: 99%

Micro cutting force model of micro-jet induced by cavitation collapse in the ultrasonic field at micro-nano scale

Ye¹,

Zhu²,

He³

2021

Preprint

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The micro-jet is the main mechanism of cavitation on materials. More and more ultrasonic cavitation assisted machining uses the micro-jet effect in the industrial field. In this paper, the micro-jet impact is considered as the micro cutting process. To deeply analyze the micro cutting mechanism of micro-jet, the size effect of materials was considered, and the micro cutting force model of micro-jet was established and solved based on the spherical indentation test theory and the strain gradient plasticity theory. The results showed that the micro cutting force and impact pressure of micro-jet with size effect are larger than those without size effect, and the micro cutting force of single micro-jet is within 2.35 N. The micro cutting force of micro-jet increases exponentially with the increase of pit radius, but only slightly increases with the increase of pit depth. When the size effect is considered or not, the impact pressure of micro-jet is 1616-2922 MPa or 1615-1980 MPa, respectively. The increase ratio of micro cutting force with size effect is , which can directly reflect the strength of size effect. The size effect is more obvious when the pit size is smaller, and the maximum increase ratio is 47.54%.The increase ratio increases nonlinearly with the decrease of pit radius and increases with the increase of pit depth. It has a strong correlation with pit radius and pit depth. This paper can provide a new theoretical viewpoint and support for the quantitative description of cavitation effect in ultrasonic assisted machining.

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Ultrasonic cavitation and vibration hybrid-assisted micro-drilling of stainless steel

Cited by 13 publications

References 20 publications

Mechanism and Experiment Study of Non-Contact Ultrasonic Assisted Grinding

Mechanism and Experiment Study of Non-Contact Ultrasonic Assisted Grinding

Cavitation Effect in Ultrasonic-Assisted Electrolytic In-Process Dressing Grinding of Nanocomposite Ceramics

Micro cutting force model of micro-jet induced by cavitation collapse in the ultrasonic field at micro-nano scale

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