Physics-Based Predictive Cutting Force Model in Ultrasonic-Vibration-Assisted Grinding for Titanium Drilling

2009 ◽  
Vol 131 (4) ◽  
Author(s):  
Na Qin ◽  
Z. J. Pei ◽  
C. Treadwell ◽  
D. M. Guo
Keyword(s):  
Cutting Force ◽  
Ultrasonic Vibration ◽  
Removal Rate ◽  
Cutting Temperature ◽  
Brittle Materials ◽  
Force Model ◽  
Rotary Ultrasonic Machining ◽  
Cutting Force Model ◽  
Input Variables ◽  
Ultrasonic Vibration Assisted Grinding

Ultrasonic-vibration-assisted grinding (UVAG) or rotary ultrasonic machining has been investigated both experimentally and theoretically. Effects of input variables on output variables in UVAG of brittle materials and titanium (Ti) have been studied experimentally. Models to predict the material removal rate in UVAG of brittle materials have been developed. However, there is no report on models of cutting force in UVAG. This paper presents a physics-based predictive model of cutting force in the UVAG of Ti. Using the model developed, influences of input variables on cutting force are predicted. These predicted influences are compared with those determined experimentally. This model can serve as a useful template and foundation for development of cutting force models in UVAG of other materials (such as ceramics and stainless steels) and models to predict torque, cutting temperature, tool wear, and surface roughness in UVAG.

Ultrasonic-Vibration-Assisted Grinding of Brittle Materials: A Mechanistic Model for Cutting Force

2011 ◽  
Author(s):  
Na Qin ◽  
Z. J. Pei ◽  
W. L. Cong ◽  
C. Treadwell ◽  
D. M. Guo
Keyword(s):  
Cutting Force ◽  
Ultrasonic Vibration ◽  
Material Removal ◽  
Mechanistic Model ◽  
Brittle Materials ◽  
Rotary Ultrasonic Machining ◽  
Input Variables ◽  
Diamond Grain ◽  
First Time ◽  
Ultrasonic Vibration Assisted Grinding

A mechanistic model for cutting force in ultrasonic-vibration-assisted grinding (UVAG) (also called rotary ultrasonic machining) of brittle materials is proposed for the first time. Fundamental assumptions include: (1) brittle fracture is the dominant mechanism of material removal, and (2) the removed volume by each diamond grain in one vibration cycle can be related to its indentation volume in the workpiece through a mechanistic parameter. Experiments with UVAG of silicon are conducted to determine the mechanistic parameter for silicon. With the developed model, influences of six input variables on cutting force are predicted. These predicted influences trends are also compared with those determined experimentally for several brittle materials.

Investigation on feed direction cutting force in ultrasonic vibration-assisted grinding of dental ceramics

2016 ◽  
Vol 231 (19) ◽  
pp. 3493-3503 ◽  
Author(s):  
Heng Meng ◽  
Kan Zheng ◽  
Xingzhi Xiao ◽  
Wenhe Liao
Keyword(s):  
Mathematical Model ◽  
Cutting Force ◽  
Ultrasonic Vibration ◽  
Abrasive Particle ◽  
Force Model ◽  
Zirconia Ceramics ◽  
Feed Direction ◽  
Input Variables ◽  
The Mathematical Model ◽  
Ultrasonic Vibration Assisted Grinding

The feasibility of ultrasonic vibration-assisted grinding in dental restoration has been preliminarily proved. Improving the machining quality of zirconia ceramics by controlling cutting force is the focus of the researchers. However, the existing feed direction cutting force model for ultrasonic vibration-assisted grinding does not take the ultrasonic vibration amplitude and frequency into account. This paper presents a mathematical model for feed direction cutting force in ultrasonic vibration-assisted grinding of zirconia under the consideration of amplitude and frequency, and assuming that brittle fracture is the primary mechanism of material removal in ultrasonic vibration-assisted grinding of zirconia. The effects of amplitude and frequency on the motion, effective cutting distance, and theoretical removal of an abrasive particle have been analyzed. Besides, the number of active abrasive particles is calculated with analyzing the influences of lateral cracks and ultrasonic vibration. The variation laws of cutting force and penetration depth of an abrasive particle during ultrasonic vibration-assisted grinding have also been analyzed. Therefore, the relationship between feed direction cutting force and input variables is predicted through the developed model. Finally, pilot experiments are conducted for the mathematical model verification. Experimental results show that the trends of input variables for feed direction cutting force agree well with the trends of the developed cutting force model. Hence, the mathematical model can be applied to evaluate the feed direction cutting force in ultrasonic vibration-assisted grinding of zirconia ceramics.

Ultrasonic-Vibration-Assisted Grinding of Titanium: Cutting Force Modeling With Design of Experiments

2009 ◽  
Author(s):  
Na Qin ◽  
Z. J. Pei ◽  
D. M. Guo
Keyword(s):  
Cutting Force ◽  
Ultrasonic Vibration ◽  
Cost Effective ◽  
Machining Process ◽  
Force Model ◽  
Force Modeling ◽  
Input Variables ◽  
Low Efficiency ◽  
Factor Interactions ◽  
Ultrasonic Vibration Assisted Grinding

Titanium and its alloys (Ti) have wide applications in industry. However, since Ti is notorious for its poor machinability, their applications have been hindered by the high cost and low efficiency. Ultrasonic-vibration-assisted grinding (UVAG) is a hybrid machining process that combines the material removal mechanisms of diamond grinding and ultrasonic machining, and it is a cost-effective machining process for Ti. The relations between cutting force and input variables have been investigated and reported. But these relations have been studied by changing one variable at time. Therefore, the interactions between cutting force and input variables have not been revealed. In this paper, a two-level five-factor full factorial design is used to study the relations between cutting force and input variables based on a cutting force model for UVAG of Ti. The main effects of these variables, and two-factor interactions and three-factor interactions of these variables are also revealed.

Rotary Ultrasonic Machining of CFRP: Design of Experiment With a Cutting Force Model

2015 ◽  
Author(s):  
Fuda Ning ◽  
Weilong Cong
Keyword(s):  
Cutting Force ◽  
Design Of Experiment ◽  
Cutting Temperature ◽  
Force Model ◽  
Drilling Process ◽  
Ultrasonic Machining ◽  
Rotary Ultrasonic Machining ◽  
Machining Processes ◽  
Cfrp Composites ◽  
Input Variables

Drilling is one of very important machining processes in many applications of carbon fiber reinforced plastic (CFRP) composites. Rotary ultrasonic machining (RUM) has been successfully used in drilling of CFRP composites to overcome poor machinability. Cutting force is one of the most important output variables for evaluating drilling process, since it will greatly influence cutting temperature, tool wear, and surface conditions. Currently, there are no reported investigations on effect of input variables on cutting force using design of experiment (DOE) method in RUM of CFRP composites. Five-variable two-level full factorial design has been conducted to study cutting force based on a mechanistic predictive model in RUM of CFRP composites. Main effects as well as interaction effects of five process variables (vibration amplitude, tool rotation speed, feedrate, abrasive size, and abrasive concentration) on cutting force are revealed.

Predictive Models for Flank Wear in Near Dry Machining

2005 ◽  
Author(s):  
Kuan-Ming Li ◽  
Steven Y. Liang
Keyword(s):  
Tool Wear ◽  
Cutting Force ◽  
Flank Wear ◽  
Cutting Temperature ◽  
Dominant Factor ◽  
Force Model ◽  
Temperature Model ◽  
Dry Machining ◽  
Cutting Force Model ◽  
Wear Model

The objective of this paper is to present a methodology to analytically model the tool flank wear rate in near-dry turning. The resulting models can serve as a basis to minimize time-consuming machining tests in predicting tool life. Analytical models, including cutting force model, cutting temperature model, and tool wear model, are presented. The cutting force model was established based on Oxley’s model with modifications for lubricating and cooling effect due to the air-oil mixture in near-dry machining. The cutting temperature was obtained by considering a moving or stationary heat source in the tool. The tool wear model contained abrasive mechanism, adhesion mechanism, and diffusion mechanism. The important factors related to this model were contact stresses and temperatures that were obtained from the cutting force model and the cutting temperature model. To develop these models, a set of cutting experiments using carbide tools on AISI 1045 steels were performed to calibrate the coefficients in the models and to verify the proposed flank wear mechanisms. The comparisons between the model-predictive flank wear and experimental results showed that the flank wear in near dry machining can be estimated well by the proposed models. It was also found that the cutting velocity was a dominant factor among the cutting conditions.

scholarly journals An Improved Cutting Force Model for Ultrasonically Assisted Grinding of Hard and Brittle Materials

2021 ◽  
Vol 11 (9) ◽  
pp. 3888
Author(s):  
Renke Kang ◽  
Jinting Liu ◽  
Zhigang Dong ◽  
Feifei Zheng ◽  
Yan Bao ◽  
...  
Keyword(s):  
Cutting Force ◽  
Cutting Forces ◽  
Experimental Studies ◽  
Brittle Materials ◽  
Grinding Force ◽  
Grinding Wheel ◽  
Force Model ◽  
Cutting Force Model ◽  
Fillet Radius ◽  
Hard And Brittle Materials

Cutting force is one of the most important factors in the ultrasonically assisted grinding (UAG) of hard and brittle materials. Many theoretical and experimental studies show that UAG can effectively reduce cutting forces. The existing models for UAG mostly assume an ideal grinding wheel with abrasives in both the end and lateral faces to accomplish material removal, whereas the important role of the transition fillet surface is ignored. In this study, a theoretical cutting force model is presented to predict cutting forces with the consideration of the diamond abrasives in the end face, the lateral face, and the transition fillet surface of the grinding tool. This study analyzed and calculated the vibration amplitudes and the cutting forces in both the normal and tangential directions. It discusses the influences of the input parameters (rotation speed, feed rate, amplitude, depth and radius of transition fillet) on cutting forces. The study demonstrates that the fillet radius is an important factor affecting the grinding force. With an increase in fillet radius from 0.2 to 1.2 mm, the grinding force increases by 139.6% in the axial direction and decreases by 70% in the feed direction. The error of the proposed cutting force model is 10.3%, and the experimental results verify the correctness of the force model.

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