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.

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.

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.

The Mechanics and Mechanisms of Material Removal in Abrasive Drilling C/E Composites

2011 ◽  
Vol 325 ◽  
pp. 244-250 ◽  
Author(s):  
Q. Wen ◽  
Hang Gao ◽  
Dong Ming Guo ◽  
B. Wang
Keyword(s):  
Cutting Force ◽  
Material Removal ◽  
Shear Failure ◽  
Mechanistic Model ◽  
Maximum Tensile Stress ◽  
Drilling Tool ◽  
Element Simulation ◽  
Single Grain ◽  
Diamond Grain ◽  
Tensile Damage

The abrasive drilling achieves high hole qualities in processing carbon/epoxy (C/E) composites. In order to investigate the cutting force and the material removal mechanism for drilling C/E composites with abrasive drilling tool, this paper presented a mechanistic model to predict the cutting force of single grain. The model assumes fibers as a beam with two ends fixed. The beam is subjected to extrusion of diamond grain and mainly fractures by tensile damage. The failure mode is then validated by finite element simulation and scratching experiment. The cutting simulation of single grain using Abaqus showed fracture occurred in the points with maximum tensile stress. The tensile damage results in many claval chips. Local fiber tensile damage is the mainly failure mechanism for the fibers, accompanying the fiber compressive failure and shear failure.

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.

scholarly journals Effect to the Surface Composition in Ultrasonic Vibration-Assisted Grinding of BK7 Optical Glass

2020 ◽  
Vol 10 (2) ◽  
pp. 516 ◽  
Author(s):  
Pei Yi Zhao ◽  
Ming Zhou ◽  
Xian Li Liu ◽  
Bin Jiang
Keyword(s):  
Surface Roughness ◽  
Ultrasonic Vibration ◽  
Material Removal ◽  
Surface Composition ◽  
Rotation Speed ◽  
Optical Glass ◽  
Machined Surface ◽  
Spindle Rotation ◽  
Ultrasonic Vibration Assisted Grinding ◽  
Ductile Removal

Because of the changes in cutting conditions and ultrasonic vibration status, the proportion of multiple material removal modes are of uncertainty and complexity in ultrasonic vibration-assisted grinding of optical glass. Knowledge of the effect of machined surface composition is the basis for better understanding the influence mechanisms of surface roughness, and also is the key to control the surface composition and surface quality. In the present work, 32 sets of experiments of ultrasonic vibration-assisted grinding of BK7 optical glass were carried out, the machined surface morphologies were observed, and the influence law of machining parameters on the proportion of different material removal was investigated. Based on the above research, the effect of surface composition was briefly summarized. The results indicated that the increasing of spindle rotation speed, the decreasing of feed rate and grinding depth can improve the proportion of ductile removal. The introduction of ultrasonic vibration can highly restrain the powdering removal, and increase the proportion of ductile removal. Grinding depth has a dominant positive effect on the surface roughness, whereas the spindle rotation speed and ultrasonic amplitude both have negative effect, which was caused by the reduction of brittle fracture removal.

Comparison of Superabrasive Tools in Rotary Ultrasonic Machining of Stainless Steel

2010 ◽  
Author(s):  
Weilong Cong ◽  
Qiang Feng ◽  
Z. J. Pei ◽  
Clyde Treadwell
Keyword(s):  
Surface Roughness ◽  
Stainless Steel ◽  
Cutting Force ◽  
Ultrasonic Power ◽  
Ultrasonic Machining ◽  
Rotary Ultrasonic Machining ◽  
Time In Literature ◽  
Reported Study ◽  
Input Variables ◽  
Superabrasive Materials

Many experiments on rotary ultrasonic machining (RUM) have been conducted to study how input variables (including tool rotation speed, ultrasonic power, feedrate, and abrasive size) affect output variables (such as cutting force, torque, surface roughness, and edge chipping) by using diamond tools. However, a literature review has revealed that there is no reported study on CBN tools in RUM. This paper, for the first time in literature, presents an investigation of RUM of stainless steel using CBN tools. Firstly, an introduction of superabrasive materials and RUM principle was provided. After presenting the experiment procedures and workpiece properties, it reports the results on tool wear, cutting force, torque, surface roughness in RUM of stainless. Finally, it discusses and compares the performances of diamond and CBN tools in RUM of stainless steel under certain conditions.

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