Rotary ultrasonic machining Research Papers (original) (raw)

2024

This paper focuses on geometry measuring of the shank cutting tools by the use of optical measuring devices. The scanning is realized in the system Atos Triplescan II and also in the system Zoller Genius 3. This paper provides a proposed methodology of shank cutting tools geometry measuring based on our scanning and measuring for the system Atos. The proposed methodology consists of the calibration, setting and tool clamping, preparation reference point and measuring in software. Part of the work also includes a comparison of measured results between the devices Atos and Zoller. This paper provides a contribution to the study of measurement geometry of the shank cutting tools.

2024, Lecture Notes in Mechanical Engineering

2024, SKIT Research Journal

Ultrasonic machining (USM) is a process used for machining material with high hardness and brittle nature that are difficult to machine. The USM has an upper hand on the other non-conventional process like electron discharge and laser beam machining which have thermal effect on workpiece. Workpiece chracteristics are also not limited by chemical and electrical properties. This paper discusses about the rotary ultrasonic drilling (RUD) machining process which is a variant of USM and the recent developments that it gone under through the RUD. This paper also reviews about the various methodology adopted by researchers to achieve optimum output parameters like Material Removal Rate, Surface roughness, Edge chipping etc. by altering the process characteristics like spindle speed, feed rate, ultrasonic power etc. as well as machine characteristics like tool type, support length etc. The paper also deals with the material used with the RUD worldwide and the findings of researchers on them.

2024, SKIT Research Journal

2024, Advances in Mechanical Engineering

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 ha...

2023, SKIT Research Journal

Rotary Ultrasonic Machining (RUM) is a productive and successful tool used for cutting and machining of fiber-reinforced polymer composites. Fiber-reinforced polymer composites have great applications which have been extensively used in aircraft workings, marine, automotive components and sporting goods. The primary machining operation is surface machining which is the most recurrently employed process on fiber-reinforced composites. However, some challenges like rough surface quality, short tool life, low machining precision and rough edges have not yet discover general applications. The ultrasonic frequency and amplitude both affect the ultrasonic vibrations. Different input parameters such as feed rate, tool rotation speed, depth of cut and ultrasonic power affect on output parameters such as removal rate of material, tool wear and surface roughness which have been studied in this research. The available literature on different machining parameters help in finding research gap in rotary ultrasonic machining process. The consequences of input machining parameters on material removal rates and surface roughness are the key findings of this research.

2023, Applied Mechanics and Materials

Efficient grinding of structural ceramics requires judicious selection of operating parameters to maximize removal rate while controlling surface integrity. Grinding of ceramics is difficult because of its low fracture toughness, making it very sensitive to cracking. In the present work, experiments were carried out to study the effect of wheel parameters such as grain size and grinding parameters like depth of cut and feed rate on the surface roughness and surface damage. The significance of the grinding parameters on the selected responses is evaluated using analysis of variance. Mathematical statistics like “Minitab” is used to analyzed the grinding conditions for maximum material removal, using a multi-objective function model, by imposing surface roughness, surface force and surface damage constraints. The choice of including manufacturer & apposes constraints on the basis of functional requirements of the component for maximizing the production rate is also embedded in the Mat...

2023, Materials Today: Proceedings

The industrial scenario demands the product to be produced in higher surface finish with minimum tool wear. Grinding is predominantly known to provide excellent surface finish among other machining processes. The scope for improvement is always exists in the processes. In the meantime, Material Removal Rate (MRR) of the procedure ought not to be affected. Since, it directly affects the productivity of the process. The composite Carbon Fibre Reinforced Plastic (CFRP) has preferred properties involving high strength-over weight extent, high shortcoming restriction, high modulus-to-weight extent, etc. Due to the nonuniform and varying in magnitude, high gratings /abrasiveness and high strength ability of the reinforcement in CFRP composites, results in difficult to-cut (surface materials) in surface grinding shapes. The conventional surface grinding process on CFRP requires high cutting force at the same time material removal rate is low. In request to decrease and eliminate these intricacies, Rotary Ultrasonic Machining (RUM) is favoured for surface grinding of CFRP composites. In this paper, interdisciplinary reviews on CFRP composites have been done under the reaction of surface grinding of the composite using rotary ultrasonic machining. This paper will give the guidelines to future research in impacts on CFRP under RUM observational studies.

2023, Research Papers Faculty of Materials Science and Technology Slovak University of Technology

Article discusses the diagnostics and possibility of monitoring cutting fluids and proposes a solution: on-line monitoring system. In regard to verify the possibility of using various methods to identify changes in the cutting fluids were... more

2023, Research Papers Faculty of Materials Science and Technology Slovak University of Technology

2023, The International Journal of Advanced Manufacturing Technology

Drilling is the oldest, most widely used manufacturing operation, but it is also quite misunderstood. As drilling accuracy and cost become crucial, a better understanding of tool behaviour is required. Unlike operations such as milling and turning, where cutting phenomena are easily observable, during drilling, the tool is confined to the material. Using a six-component dynamometer (Couétard Y (1993) Capteur de forces à deux voies et application à la mesure d'un torseur de forces. Brevet français 93403025.5) enables the complete identification of forces and torques applied by the tool to the workpiece (Couétard Y, Cahuc O, Darnis Ph (2001) Mesure des 6 actions de coupe en fraisage grande vitesse. Third International Conference on Metal Cutting and high speed machining, Metz, 27-29 Juin, pp. 37-42). Therefore, it is possible to take into account radial components (forces and

2023, Journal of Manufacturing and Materials Processing

Although laser drilling of carbon fibre-reinforced polymer (CFRP) composites offers the advantages of zero tool-wear and avoidance of fibre delamination compared with mechanical drilling, it consumes considerably more energy during the drilling process. This research shows that by using a new, stepped parameter parallel ring laser hole drilling method, an energy saving of 78.10% and an 18.37 gCO2 reduction for each hole, while improving productivity by more than 300%, can be achieved in laser drilling of 6 mm diameter holes in CFRP sheets of 2 mm in thickness, compared with previous laser drilling methods under the same drilling quality. The key reason for this is an increase in energy input to the inner rings enabling more rapid removal of the material, while the lower energy input for the outer ring provides a shielding trench to reduce the heat loss into the parent material. The results are compared with single-ring laser drilling and multiple-ring laser drilling with constant pr...

2023

2023, MATEC Web of Conferences

Surface roughness is the key aspect which could increase the application of float glass by enhancing the machined hole quality. Glass is extensively used in microfluidic devices, bio-medical parts and biosensors. The core objective of the research study is to optimize the best parametric combination to achieve the least amount of surface roughness. The three major parameters which are used for designed experimental study are spindle speed, ultrasonic amplitude and feed rate. The least value of surface roughness is noticed at spindle speed (5000 rpm), vibration amplitude (20 μ m) and feed rate (6 mm/min) which be adopted for increasing its functional application. Consequently, after optimizing the parameters, least value of surface roughness at hole internal region is revealed as 1.09 μm.

2023, Journal of Manufacturing Processes

Rotary ultrasonic machining (RUM) shows capabilities in several manufacturing applications specifically for fabrication of high-quality features on ceramic materials. However, surface fracturing and edge chipping are the persistent issues during the RUM of ceramic materials. This research reports an experimental investigation to analyze the machinability of the biolox forte ceramic by milling microchannels using RUM. Machinability is studied by analyzing the performance measures such as the surface roughness, surface morphology, edge chipping and tool wear. The effects of the five major RUM input parameters including spindle speed, feed rate, depth of cut, vibration amplitude, and vibration frequency are taken into consideration on the machinability of the biolox forte material. An attempt has been made to characterize the material removal behaviour within the microchannels. The results reveal more brittle fracturing and deep pits on the channel bed as compared to the channel sidewall due to the difference in the cutting action of the RUM tool. Furthermore, it is observed that the channel sidewalls always show a coarse machined region near the top edge and a relatively smooth machined region up to the channel bed. The energy dispersive spectroscopy (EDS) analysis reveals that no change in the composition of the biolox forte occurs and no traces of tool material are observed in the microchannels. The scanning electron microscopy (SEM) analysis of the tool shows that the plastics deformation, attritious wear, and the tool edge rounding and chipping are the primary tool wear mechanisms. By selecting the appropriate RUM parameters, microchannels with good surface finish (Ra =0.21 μm), smoothed morphology and minimal edge chipping (16.3 μm) can be milled on the biolox forte material.

2023

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2023, Materials and Manufacturing Processes

The study concerned with optimization of modulation-assisted drilling (MAD) operation for a difficult-tocut material Ti6Al4 V was carried out via response surface method (RSM). Conventional drilling (CD) has been explored for comparison purposes. Experiments have been designed according to the Central Composite Design (CCD). The impact of machining input parameters on surface roughness (SR), machining power consumption, and tool wear (TW) was investigated for both cases. Pilot experiments were carried out to find out the best modulation range. Further drilling experiments were carried out varying feed rate, spindle speed, and tool diameter. Multiple regression analysis using RSM established relationships between these parameters and responses. ANOVA was used to develop and test the mathematical models. The models were effective in predicting the responses for MAD of Ti6Al4 V. The optimum drilling parameters are a tool diameter (TD) of 2 mm, feed rate (FR) of 0.030 mm/rev and spindle speed (SS) of 2176.87 rpm. SEM and EDS analyzes were performed to investigate the machined surfaces. From the study, it can be concluded that MAD is a promising machining process for difficult-to-cut materials with comparatively less thrust force, surface roughness and tool wear.

2023, CIRP Journal of Manufacturing Science and Technology

A dynamic model for multispan rotating gundrill shaft with thrust force and coolant pressure is proposed using rotational Euler-Bernoulli beam model (REB) through energy approach. From the numerical simulation, it is found that the 1st critical RPM of the rotating gundrill shaft increases tremendously as coolant pressure increases. The proposed model is incorporated with a straightness model. Experimental verification for the proposed model is presented. It is found that by using the combination of higher pressure (2000 psi) and rotational speed (1600 rpm), a straighter hole within industrial tolerance is achieved in gundrilling of Inconel-718.

2023, Ultrasonics

Carbon fiber reinforced plastic (CFRP) composites are very difficult to machine. A large number of holes need to be drilled in CFRP for many applications. Therefore, so it is important to develop cost-effective drilling processes. CFRP has been drilled by rotary ultrasonic machining (RUM) successfully. The literature has reports about the effects of input variables on output variables (including cutting force, torque, surface roughness, tool wear, and workpiece delamination) in RUM of CFRP. However, there are no reports on power consumption in RUM of CFRP. This paper reports the first study on power consumption in RUM of CFRP. It reports an experimental investigation on effects of input variables (ultrasonic power, tool rotation speed, feedrate, and type of CFRP) on power consumption of each component (including ultrasonic power supply, spindle motor, coolant pump, and air compressor) and the entire RUM system.

2023, Journal of Reinforced Plastics and Composites

Drilling is involved in many applications of carbon fiber–reinforced plastic composite. Twist drilling is widely used in industry. Rotary ultrasonic machining has been successfully tested to drill holes in carbon fiber–reinforced plastic. However, there are no reports on comparisons between rotary ultrasonic machining and twist drilling of carbon fiber-reinforced plastic. This paper compares rotary ultrasonic machining and twist drilling of carbon fiber–reinforced plastic in six aspects (cutting force, torque, surface roughness, delamination, tool life, and material remove rate). Experimental results show that rotary ultrasonic machining is superior in almost all these aspects.

2023, Journal of Composite Materials

Drilling is involved in many applications of carbon fiber-reinforced plastic (CFRP) composites. Rotary ultrasonic machining (RUM) has been successfully employed to drill holes in CFRP using either cutting fluid or cold air as coolant. However, there are no reported studies to compare the results in RUM of CFRP using these two types of coolant. This article, for the first time, presents an experimental study to compare cutting force, torque, surface roughness, burning of machined surface, and tool wear in RUM of CFRP using these two types of coolant. This study will result in knowledge about machining conditions under which it is feasible to use cold air instead of cutting fluid and differences in machined hole quality produced using cold air vs. cutting fluid.

2023, International Journal of Manufacturing Technology and Management

Rotary ultrasonic machining (RUM), a hybrid machining process combining the material removal mechanisms of diamond grinding and ultrasonic machining, has been recognised as a reliable and cost-effective machining method for hard-to-machine materials such as advanced ceramics. There exist a number of articles on this process, but no one has reported systematic studies on coolant effects. In this paper, the air-operated double diaphragm pump is used for the first time in rotary ultrasonic machining to develop a novel coolant system to study the coolant effect on RUM performances, including vertical cutting force, material removal rate and surface roughness. Experiments with different coolant delivery modes are conducted and the material removal process in rotary ultrasonic machining when employing the new coolant system is discussed.

2023, International Journal of Manufacturing Research

Rotary ultrasonic machining (RUM) is a nontraditional drilling process. It has been used to drill not only brittle but also ductile materials. It was observed that the surface roughness of the drilled hole near the entrance side was better than that near the exit side. However, explanations about this observation could not be found in the literature. This paper aims to provide explanations about this observation. It presents three hypotheses and their testing via experiments and simulations.

2023, Composites Part B: Engineering

Rotary ultrasonic machining (RUM) has been successfully used to drill Ti (titanium and its alloy), CFRP, and CFRP/Ti stacks. In all studies on RUM reported in the literature, feedrate was fixed during each experimental test. It has been shown that low feedrate should be used for RUM of Ti, but RUM of CFRP could be done using feedrate ten times higher. This paper, for the first time, reports a study on RUM of CFRP/Ti stacks using variable feedrate (high feedrate for CFRP and low feedrate for Ti). It also makes comparisons on RUM of CFRP/Ti stacks using fixed and variable feedrate.

2023, Journal of Reinforced Plastics and Composites

Carbon fiber reinforced plastic (CFRP) composites are in demand for a variety of applications due to their superior properties. Drilling is involved in many CFRP applications. Experiments have been successfully conducted to use rotary ultrasonic machining (RUM) for CFRP drilling. These experiments were conducted using either cutting fluids or cold air as coolant. RUM of CFRP composites without cutting fluids can eliminate problems caused by cutting fluids, such as high cost of cutting fluids and their disposal, pollution to the environment, and harm to human health. However, dry machining (machining without cutting fluids) also has its limitations, such as burning of machined surface, more friction and adhesion between tool and workpiece, and reduction in tool life. This article presents an experimental study on feasible regions in rotary ultrasonic machining of CFRP using cold air as coolant. Three criteria (burning of machined surface, delamination, and tool blockage) were used to...

2023, Scientific Reports

This research is focused on the drilling of Nickel based super alloy with diamond metal core drill and identified the significant parameters of rotary ultrasonic machining that optimise the machining rate (MR) and surface quality. Four general parameters: workpiece material, workpiece thickness, tool material, and tool size; and four RUM parameters: tool rotational, feed rate, ultrasonic power rating, and abrasive grit size of the tool were tested against and surface quality of the cut. The results indicated that the maximum value of MR of 0.8931mm 3 /sec is acquired at higher level of tool rotation, feed rate, ultrasonic power and moderate level of abrasive grit size of diamond. The minimum surface roughness (R a) 0.554 µm is observed at higher level of rotational rotation, Moderate value of feed rate, ultrasonic power and diamond abrasive grit size. In addition, for single-objective and multi-objective functions, the particle swarm optimization (PSO) approach is used to find the optimum values for process parameters. Furthermore, a scanning electron microscope is also utilized to check the machined surface after RUM. It is concluded that microcracks are observed on the machined surface. With the development of aircraft engine technology, composite and hard-to-cut materials are being used in the new engines more and more. This finding shows that there is a greater need for processing techniques and component capabilities for the machining of challenging materials. A nickel based super alloys are unique class of metallic materials with a remarkable combination of elevated temperature strength, toughness, and resistance to deterioration in corrosive or oxidising conditions 1. Figure 1 shows the advancement in nickel based super alloy's temperature capability which has increased year by year owing to the advanced processing, alloy development, use of the thermal barrier coatings, innovative and effective cooling schemes 2. The components of aircraft engine, such as the casing, compressor discs, bearing ring, blades, turbine disc, and other parts operating in the high temperature, are made with nickel-based superalloys because of their high strength, strong corrosion resistance, excellent thermal fatigue properties, and thermal stability 3. The numerous superalloys based on nickel that are used in jet engines are listed in Fig. 2. Fifty percent parts of the jet engine is made by Inconel 718. Inconel is a Ni-Fe-Cr alloy 4. However, the tensile strength Inconel 718 can reach 1393 MPa at room temperature. The component's machining become hard due to its machinability. It has machinability only 8-20% of steel which leads to inefficient processing. Additionally, the machining of nickel-based superalloys results in increased tool oxidation wear, adhesive wear, mechanical & diffusion wear, and, which reduces tool life. For instance, the rough and fine drilling of a nickel-based superalloy blade with a medium drilling length requires more time. For machining of super alloys, a frequent tool wear is considered to be the direct factor that limits the processing efficiency, while the sharp temperature rise caused by the heavily work-hardened surface being machined is a key factor to accelerate the tool wear 5. According to Habeeb et al. 6 , thermally induced cracking was the main reason for tool failure at high cutting rates. This happens as a result of the edges being subjected to a significant amount of thermal shock as a result of the high temperature brought on by fast cutting speeds and significant temperature change 7. Conventional drilling is commonly faced with some difficulties due to heat localization in the cutting zone resulted by drill embedding in workpiece. The cutting temperature directly affects dimensional accuracy of drilled hole, surface quality, and tool life. Lofti et al. used ultrasonic assisted drilling under presence of nano-fluid minimum quantity

2023, The International Journal of Advanced Manufacturing Technology

A new hybrid cutting-abrasive machining tool (turn-grind) is detailed for high-quality machining of fibre reinforced polymer (FRP) composites, comprising single point carbide inserts electroplated with multi-layers of diamond abrasives 120 μm grain size, to form an abrasive region adjacent to an abrasive-free cutting edge. Experimental data are presented for turning tubes of CFRP and GFRP. The surface quality of workpieces after machining was evaluated through surface roughness measurements and SEM imaging. Cutting-only caused more defects such as delamination and fibre to pull out. Compared with cutting-only, contact and non-contact measurement of surface roughness (Ra) in both axial and radial directions showed an increase for CFRP and GFRP with roundness error reduced to 50%. No significant increase in cutting force was observed.

2023, SKIT Research Journal

2023

Poly-crystalline cubic boron nitride (PCBN) is the hardest material beside diamonds. Generally, so hard materials could not be machined by conventional machining technologies. For this purpose, advanced machining methods have been designed. Rotary ultrasonic machining (RUM) and laser beam machining (LBM) are included among them. This contribution investigate and compare these advanced methods during machining of PCBN. In experi-ments, a tool for friction stir welding (FSW) was manufactured. The main evaluated attributes was shape accuracy and dimension precision. When shape accuracy is not sufficient, welding process is negatively affected (lower tool life, improper weld parameters). And when dimensions of welding tool are different, it cannot be used for demanded sheet thickness. According to the performed experiments, RUM achieved good enough shape accuracy, but inadequate dimension properties. For LBM it was vice versa.

2022

Inconel 718 is a high nickel content super alloy possessing high strength at elevated temperatures and resistance to oxidation and corrosion. The non-traditional manufacturing process of Rotary ultrasonic machining (RUM) possesses many advantages over traditional machining during the manufacture of Inconel 718 parts. An experimental investigation was conducted to determine the main RUM parameters which contribute to effects the metal removal rate and surface roughness of Inconel 718. It was found that feed rate is the most critical parameter in RUM.

2022

Machining creates a wide diversity of objects used on a daily and is one of the most significant techniques used in the machining industry. Things such as tools and equipment are shaped with a high-level of accuracy via quality precision machining that utilizes sophisticated software such as CAM (computer aided manufacturing) or CAD (computer aided design) to interpret blueprint designs. A number of materials, including steel, copper, graphite, titanium and plastics, to name a few, can be cut with optimal precision. To organize and complete your projects in a timely, quality and financially responsible manner, you need to schedule projects carefully. Effective project scheduling plays a crucial role in ensuring project success. To keep projects on track, set realistic time frames, assign resources appropriately and manage quality to decrease product errors. This typically results in reduced costs and increased customer satisfaction. Important factors include financial, documentation...

2022, Lecture Notes in Mechanical Engineering

2022, International Journal of Manufacturing Research

Super alloy has extensive engineering applications in nuclear industries owing to its outstanding performance characteristics at elevated temperature. More than 30% of consumption in nuclear industries is super alloy. A number of holes are required to be drilled into super alloys for their final stage assembly. During conventional machining process, excessive heat is generated, which is the cause of heat treated zone that further affect the life and performance of the product. To overcome this difficulty, a rotary ultrasonic machining method came into existence to machine super alloys by hybrid cutting action (vibratory and rotary) of diamond impregnated core drill. This study focuses on the machining characteristics of super alloy by RUM process. The empirical modelling of process parameters of RUM is carried out for super alloy (Inconel 718) using an experimental design approach called response surface methodology. Material removal efficiency of RUM and surface topography of the machined material are studied. The results reported that for quality and productivity aspect, the feed rate in RUM is found a most critical factor.

2022, Iranian Journal of Science and Technology, Transactions of Mechanical Engineering

Manufacturing industries are moving toward super alloys owing to their unique features. In this article, the performance analysis of nickel-based super alloys has been studied on rotary ultrasonic machining (RUM) by varying the tool shapes and abrasive size of the diamond. The output quality of the machined part has been evaluated in terms of conicity and circularity of the hole. The machining process has been carried out by considering all the necessary RUM parameters like tool rotation, tool feed rate and ultrasonic power. The experimental setup validated that the lower value of conicity and circularity can be obtained at: tool rotation 4600 rpm, feed rate 0.013843 mm/s, ultrasonic power 60% abrasive size 140 mesh and using slotted tool. The variation in the abrasive size and the tool shapes has a significant effect on the performance of the machining.

2022, Materials Today: Proceedings

Machining of ceramic material is difficult to achieve with conventional machining methods. The rotary ultrasonic machine plays a crucial role in the machining of such harder materials. During machining of ceramics, the edge chipping is one of the crucial factors which affect the quality of the product. This factor must be at the lowest level of better quality and minimum wastage. This paper demonstrates the mechanism of fracture and effect of support length on edge chipping size during the experimental study of advance ceramic (Al 2 O 3). The investigation results showed that edge quality can be improved by increasing the support length to the workpiece.

2022, Advances in Manufacturing

Super alloys are intensively used in various industries, especially in the aerospace industry, because of their special characteristics. A number of holes are sometimes required to be drilled into super alloys for aircraft at their final stage assembly. In the present study, a hybrid ultrasonic machining method, called rotary ultrasonic machining (RUM), was successfully used in super alloy drilling. The empirical modeling of the process parameters of RUM was performed for the super alloy (Inconel 718) using an experimental design approach, called response surface methodology (RSM). Parameters, namely tool rotation, feed rate, ultrasonic power, and abrasive grit size, were selected as input variables. The others were kept constant. The performance was measured in terms of the machining rate and the surface roughness. The developed models were found to be reliable representatives of the experimental results with prediction errors less than ±5%. Moreover, the feed rate for the quality and productivity aspect was found to be the most critical factor. The optimized values of the machining rate and the surface roughness achieved through a multi-response optimization were 0.9 825 mm 3 /s and 0.951 lm, respectively.

2022, International Journal of Manufacturing Research

Nickel-based alloys have numerous potential engineering applications. However, their widespread applications have been hindered by the elevated machining cost. There is a crucial need for commercial and cost effective machining processes for Ni-based super alloys. Rotary ultrasonic machining (RUM) is a hybrid machining process that combines the material removal mechanisms through diamond grinding and ultrasonic vibration (USM), resulting in higher machining rate than those obtained by conventional USM. Before going to the production run, it is necessary to conduct performance analysis followed by pilot experimentation for newer material. Relationships between desired outcome and the controllable machining parameters have been deducing. However, the relationships have been studied by screening the experiments. In this paper, a three-factor two-level factorial design followed by steepest ascent is utilised to find conditions for final experimentation.

2022, Silicon

In the current research, rotary ultrasonic machining was used to drill holes in quartz material. The effect of different RUM parameters namely tool feed rate, tool rotational speed and ultrasonic power on material removal rate and surface roughness has been studied experimentally. The response surface methodology with central composite design has been used to design the experiments. From the desirability approach, the optimum setting of the rotary ultrasonic machining parameters was found to be the tool rotational speed of 4968 rpm, feed rate of 0.55 mm/min, and ultrasonic power of 80% for achieving the maximum MRR of 0.2135 mm3/s and minimum SR of 0.3685 μm. Microstructure analysis of the machined surface was performed by using scanning electron microscopy in order to study the mechanisms of material removal under the different settings of RUM parameters. It was observed that at very low feed (0.08 mm/min) and high rpm (5681) the material is predominantly removed by plastic deformation whereas at high feed (0.92 mm/min) and low rpm (2318) the material is removed by brittle fracture.

2022, IOP Conference Series: Materials Science and Engineering

Micro-channels are considered as the essential part of several medical applications such as microfluidics devices, lab on a chip, microbiology, etc. In most applications, fluid flow is required to pass through certain microchannels. The fluid flow characteristics such as flow rate and fluid dynamics are mainly accomplished based on the surface quality and dimensional accuracy of the microchannels. In this study, the microchannels are fabricated on zirconium oxide (ZrO2) using rotary ultrasonic machining (RUM). A full factorial design of experiments is employed in order to detect the influences of key input parameters of RUM including cutting speed (S), feed rate (FR), depth of cut (DOC), frequency (F) and amplitude (A) on surface roughness (Ra), edge chipping (EC), depth error (DE) and width error (WE) of the milled microchannels. Multi-objective genetic algorithm (MOGA) was employed to determine the optimal parametric conditions for minimizing the values of Ra, EC, DE, and WE of th...

2022, MATEC Web of Conferences

2022, Composites Part B: Engineering

Though Fibre Reinforced Composites (FRCs) can be manufactured with minimum damage using the state-of-theart-innovative practices, inevitable machining operations on them during functional applications may invite further damages in matrix, fibre and interfaces. Surface grinding in its various capacities and hybrid forms has been demonstrated as one of the potential techniques for material removal in FRCs. However, effects of grinding forces on damages such as trans-laminar cracks in conventional grinding is proportional to the depth of cut for all fibre orientations. This paper introduces a new methodology referred to as eccentric sleeve grinding (ESG), with an intermittent progressive cutting strategy to minimize the machining defects on FRCs. Configuration of ESG will establish an eccentric grinding wheel rotation with cutting and non-cutting zones for abrasive grains, establishing a step-by-step cutting scheme without severe fibre-matrix fracture or fibre pull-out. A mathematical model for ESG is derived to assess the grinding forces and material removal, with experimental validation using conventional aluminium oxide wheel on bi-directional carbon fibre reinforced composite. The significantly lower magnitude of grinding forces, improved grinding force ratio and reduced surface roughness were observed in ESG, in comparison with conventional surface grinding for all the selected depths of cut from 20 to 100 μm. Microscopic topography studies on surfaces generated through conventional and eccentric sleeve grinding were clearly illustrating the effectiveness of the progressive cutting strategy in ESG. The ESG configuration presented in this paper can be adopted appropriately for minimal damage machining of FRCs, even using a traditional surface grinding machine.

2022

There are some conventional cutting techniques but Abrasive Water Jet (AWJ) is a modern one. It has been increasingly using in the industry since the 1980s. AWJ cutting process allows cutting of various materials, from soft materials to brittle materials, from ceramic materials to composite materials and it has quickly become a part of non-legacy cutting methods. The aforementioned material types are used not only for airborne parts but follow-on-support phase parts also. Aircraft fly "only" with airworthy<br> parts and components and it requires very stiff manufacturing systematic. Because of its competitive environment and high technology, the aviation industry requires a fast, precise and cost-effective production process. Airworthy part design and production processes are clearly described by national and international aviation authorities. The reason why AWJ rapidly gaining a place within the aviation industry is that the material cutting efficiency is high and ...

2022, Ultrasonics

2022, International Journal of Manufacturing Technology and Management

Soda glass is a difficult-to-machine material widely used in industry. In this work, ultrasonic-assisted milling (UAM) of soda glass is investigated and compared to conventional milling (CM). Statistically designed experiments are conducted with and without cutting fluid at different levels of the spindle speed, feedrate, depth of cut, and tool particle-concentration. The significant factors and their interactions are identified by modelling the process parameters and the corresponding responses in terms of cutting forces and moment. Results show a reduction of axial cutting force and moment at higher spindle speed and lower feedrate and depth of cut. The application of ultrasonic vibration-assistance and cutting fluid demonstrates a significant effect on the axial cutting force and moment.

2022

Sisal fiber is abundantly available in Ethiopia and both sisal and glass fibers have low density, cost, and high mechanical performance. This research aims to investigate quality of drilled hole of hybrid sisal-glass fiber reinforced epoxy composites (HSGFREC) material using roundness error, surface roughness, and material removal rate as quality characteristics. As well, Taguchi and GRA methods were used to analyze and obtain optimum drilling parameters. The sample was fabricated using hand lay-up technique with a 40% volume fraction of fibers (sisal: 15% and glass: 25%) and 60% of epoxy as matrix material with a 1:10 volume ratio of hardener. The experimental results demonstrated that for obtaining low roundness error, reduced surface roughness and maximized MRR, feed rat, is the most significant parameter among all drilling parameters. And the optimum drilling parameters is spindle speed of 600rev/min, feed rate of 0.3mm/rev, drill bit diameter of 8mm, and cutting fluid ratio of 1%. As the results show, and compared with other researcher findings, the challenge in drilling of HSGFREC materials can be reduced by optimizing its drilling parameter and exploit the applicability for automotive parts and other body panels.

2022, Journal of Manufacturing Processes

Carbon fiber reinforced plastic (CFRP) composites were attractive in lots of applications, in which surface machining processes were always needed after molding fabrication processes to achieve the final functional surface geometry with desired accuracy. To improve the effectiveness and efficiency, rotary ultrasonic surface machining (RUSM) had been applied in processing CFRP composites. With the assistance of vertical ultrasonic vibration in RUSM, cutting forces were significantly reduced, but the surface roughness was increased. To improve the surface conditions and additionally reduce the cutting force for RUSM, the applied ultrasonic vibration should be aligned with surface generation direction (namely horizontal feeding direction). Up till now, there were no reported investigations on RUSM with horizontal vibration and 3D elliptical ultrasonic vibration, formed from the combination of horizontal and vertical ultrasonic vibrations. In this investigation, the horizontal and 3D elliptical ultrasonic vibrations were applied in RUSM. The comparisons among RUSM with 3D elliptical ultrasonic vibration, RUSM with horizontal ultrasonic vibration, and the surface machining without ultrasonic vibration on machining performance and surface quality were conducted. Experimental results showed that RUSM with horizontal ultrasonic vibration reduced both cutting force and surface roughness. With the application of 3D elliptical ultrasonic vibration, both cutting force and surface roughness can be further decreased. The critical horizontal ultrasonic frequency for the overlapping of abrasive grains' trajectories was analyzed. The mechanisms of RUSM with both horizontal and 3D elliptical ultrasonic vibrations and the reasons for both cutting force decreasing and surface roughness decreasing were also investigated.

2022, Ultrasonics

Rotary ultrasonic machining has been successfully explored in surface machining of carbon fiber reinforced plastic (CFRP) composites. It has been proven to be an effective and efficient CFRP machining method. Both theoretical and experimental investigations have been conducted with the assumption that the CFRP is removed by brittle fracture removal mode. However, in brittle material machining, ductile flow phenomenon still exists. Ductile scratching marks are also observed on the machined CFRP surfaces. It is still unknown that what actual material removal modes are under different machining variables. To investigate the material removal mechanisms in rotary ultrasonic surface machining (RUSM) of CFRP, single abrasive scratching tests were conducted. The scratching induced characteristics and scratching forces were analyzed. Both the ductile removal mode and the brittle fracture removal mode were observed and identified in both carbon fiber layers and epoxy resin layers on the machined marks by using scanning electron microscopy (SEM) imaging. With the increase of scratching depth, the material removal mode of CFRP was changed from the ductile removal mode to the brittle fracture mode. From the analysis of kinematic trajectory of diamond grain, the scratching cutting forces were decreased in the tests with the assistance of ultrasonic vibration under the same machining variables. The generation mechanisms of the delamination were analyzed and discussed.

2022, International Journal of Mechanical Sciences

This is a PDF file of an unedited manuscript that has been accepted for publication. As a service to our customers we are providing this early version of the manuscript. The manuscript will undergo copyediting, typesetting, and review of the resulting proof before it is published in its final form. Please note that during the production process errors may be discovered which could affect the content, and all legal disclaimers that apply to the journal pertain. Highlights  A cutting force model in RUM with horizontal ultrasonic vibration is explored.  The tool-workpiece interaction is intermittent.  The kinematic moving motions and trajectories of a single abrasive are discussed.  The effective cutting time during one cycle of ultrasonic vibration is analyzed.  The relationship between MRR and the impact force is established.

2022, The International Journal of Advanced Manufacturing Technology

The superior properties make carbon fiber-reinforced plastic (CFRP) composites attractive in many applications. After CFRPs' molding processes, additional machining processes are needed to produce final functional shapes with dimensional precision. Edge trimming is the primary process to cut the edge of CFRP composites. To reduce or further solve the problems in traditional machining processes, edge trimming of CFRP composites with rotary ultrasonic machining (RUM) has been proposed and conducted in this investigation. In RUM edge trimming processes, two different tool orientations (RUM edge trimming with tool end face and RUM edge trimming with tool side face) can be performed. The comparisons of machining performance and machined surface quality between these two different RUM edge trimming processes have been conducted. Smaller ultrasonic vibration amplitude in RUM using tool end face or larger ultrasonic vibration amplitude in RUM using tool side face produces smaller surface roughness. Lower feeding-directional cutting force, lower normal cutting force, and lower resultant force are generated in the process using tool side face. RUM using tool end face produces smaller surface roughness, smaller debris width, microcracking, flowed matrix on machined CFRP surfaces, etc.