Experimental study on ultrasonic elliptical vibration cutting of hardened steel using PCD tools

2011 ◽  
Vol 211 (11) ◽  
pp. 1701-1709 ◽  
Author(s):  
Xinquan Zhang ◽  
A. Senthil Kumar ◽  
Mustafizur Rahman ◽  
Chandra Nath ◽  
Kui Liu
Keyword(s):  
Experimental Study ◽  
Hardened Steel ◽  
Elliptical Vibration Cutting ◽  
Vibration Cutting ◽  
Elliptical Vibration ◽  
Pcd Tools ◽  
Ultrasonic Elliptical Vibration

A Study on Ultrasonic Elliptical Vibration Cutting of Hardened Steel Using PCD Tools

2010 ◽  
Author(s):  
Xinquan Zhang ◽  
Chandra Nath ◽  
A. Senthil Kumar ◽  
Mustafizur Rahman ◽  
Kui Liu
Keyword(s):  
Surface Roughness ◽  
Stainless Steel ◽  
Hardened Steel ◽  
Machining Parameters ◽  
Elliptical Vibration Cutting ◽  
Vibration Cutting ◽  
Diamond Tools ◽  
Elliptical Vibration ◽  
Pcd Tools ◽  
Ultrasonic Elliptical Vibration

Ultraprecision machining of hardened steel by the conventional cutting (CC) technique using diamond tools is impossible because of highly chemical affinity between carbon and iron at higher temperature during machining. An intermittently cutting technique, namely, ultrasonic elliptical vibration cutting (UEVC) technique has been being applied for high-quality machining of various difficult-to-cut materials for the last decade. However, study on machining of hardened stainless steel using polycrystalline diamond (PCD) tools applying this cutting technique has not been reported yet. This study presents an experimental study on UEVC of hardened stainless steel (a typical Stavax of 49 HRC) using PCD tools. Face cutting experiments have been carried out to investigate the effects of conventional machining parameters: depth of cut, feed rate, and spindle rotational speed on the performance parameters such as cutting force, tool flank wear, surface roughness and chip formation. A minimum surface roughness Ra value of 10 nm, measured by a stylus profilometer, was achieved. It can be concluded that, while applying UEVC technique, the inexpensive PCD tools compared to the single crystal diamond tools can be effectively applied to obtain optical surface for producing precise dies and molds from hardened steel.

Development and optimization of ultrasonic elliptical vibration cutting device based on single excitation

2021 ◽  
pp. 1-29
Author(s):  
Sen Yin ◽  
Zhigang Dong ◽  
Yan Bao ◽  
Renke Kang ◽  
Wenhao Du ◽  
...  
Keyword(s):  
Cutting Speed ◽  
Tungsten Alloy ◽  
Asymmetric Structure ◽  
Diamond Cutting ◽  
Elliptical Vibration Cutting ◽  
Vibration Cutting ◽  
Elliptical Vibration ◽  
Technical Capability ◽  
Diamond Cutting Tool ◽  
Ultrasonic Elliptical Vibration

Abstract Ultrasonic elliptical vibration cutting (UEVC) technique, as an advanced cutting method, has been successfully applied to machine difficult-to-cut materials for the last decade. In this study, the mechanism of the elliptical vibration locus caused by the “asymmetric structure” of the horn was analyzed theoretically firstly, and the corresponding relationship between the degree of asymmetry and the elliptical vibration locus was determined based on finite element method (FEM). Then an efficient single-excitation UEVC device with “asymmetric structure” was developed and optimized. The resonant frequency of the device was 40.8 kHz, and the amplitude reached 12.4 µm, which effectively broke the limitation of cutting speed in UEVC. Finally, the UEVC device's performance was tested, and the advantages in improving the tungsten alloy surface quality and reducing diamond cutting tool wear validated the technical capability and principle of the proposed device.

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