Research on Ultrasonic Aided Fixed-Abrasive Lapping Technology for Engineering Ceramics Cylindrical Part

2016 ◽  
Author(s):  
Feng Jiao ◽  
Bo Zhao
Keyword(s):  
Surface Quality ◽  
Ultrasonic Vibration ◽  
Tangential Force ◽  
Abrasive Particle ◽  
Cylindrical Part ◽  
Depth Of Cut ◽  
Machining Accuracy ◽  
Engineering Ceramics ◽  
Vibration Assistance ◽  
Fixed Abrasive

As the final machining procedure of precision components, lapping is often regarded as an important step affecting surface quality, machining accuracy and machining efficiency. Due to some drawbacks of free-abrasive lapping such as deep scratches on the lapped surface, lower lapping efficiency for lower lapping speed, severe waste of abrasive, high processing cost, and so on, fixed-abrasive lapping technology was put forward and developed recently. Meanwhile, considering the unique advantages of the ultrasonic vibration aided machining in the processing of hard-brittle materials such as engineering ceramics, optical glass, etc. and the influence of ultrasonic vibration on the self-sharpening characteristic of abrasive pellet, a novel ultrasonic aided fixed-abrasive lapping technology for engineering ceramics cylindrical part is put forward and corresponding lapping device is developed in this paper. Through theoretical analysis on the ultrasonic aided lapping mechanism, it is found that the value and direction of grain movement speed will change due to the superimposition of ultrasonic vibration, which will lead to the change of cutting angles and further affect the lapping performance. Assuming every abrasive particle is a cutting insert, under the assistance of axial ultrasonic vibration, negative rake of the grain will increase, even change to positive value, so as to sharpen the lapping grains and benefit the lapping processing. Moreover, when ultrasonic vibration is superimposed to the lapping tool, motion locus of abrasive grains will present sinusoid. As a result, the locus of single grain may self-interfere in actual lapping process and make blank cutting. So the depth of cut of abrasive grain will increase under the same lapping pressure, leading to the increase of MRR under the same lapping conditions. Finally, a series of contrast lapping experiments were carried out and some lapping characteristics were researched. Experimental results show that ultrasonic vibration assistance can help to heighten material removal rate, smoothen the waveform of tangential force, reduce the average tangential force and improve surface quality. Ultrasonic aided lapping with fixed abrasive is a high efficiency and precision processing technology for engineering ceramics cylindrical part.

Research on Ultrasonic-Assisted Fixed-Abrasive Lapping Technology for Engineering Ceramics Cylindrical Part

2017 ◽  
Vol 5 (2) ◽  
Author(s):  
Feng Jiao ◽  
Bo Zhao
Keyword(s):  
Ultrasonic Vibration ◽  
Material Removal ◽  
High Efficiency ◽  
Removal Rate ◽  
Tangential Force ◽  
Cylindrical Part ◽  
Engineering Ceramics ◽  
Machining Quality ◽  
Ultrasonic Assisted ◽  
Fixed Abrasive

Lapping is a key processing step for precision parts, which directly affects machining quality, precision, and efficiency. Due to some drawbacks of free-abrasive lapping such as deep scratches on the lapped surface, lower lapping efficiency for lower lapping speed, severe waste of abrasive, high-processing cost, and so on, conventional fixed-abrasive lapping (CFL) technology was proposed and developed recently. Meanwhile, considering the unique advantages of the ultrasonic-assisted machining during the processing of those hard and brittle materials and the effect of ultrasonic vibration on the self-sharpening characteristic of abrasive pellet, a novel ultrasonic-assisted fixed-abrasive lapping (UAFL) technology is put forward and corresponding lapping device for engineering ceramics cylindrical part is developed in this paper. Meanwhile, UAFL mechanism and characteristics were studied theoretically and experimentally. Research results show that superimposed ultrasonic vibration changes the lapping movement characteristics and material removal mechanism to a certain extent, helping to heighten material removal rate, smoothen the waveform of tangential force, reduce the average tangential force, and improve surface machining quality. UAFL can be regarded as a high efficiency and precision processing technology for engineering ceramics cylindrical part.

Comparative experimental research in turning of 304 austenitic stainless steel with and without ultrasonic vibration

2016 ◽  
Vol 231 (15) ◽  
pp. 2885-2901 ◽  
Author(s):  
Yingshuai Xu ◽  
Ping Zou ◽  
Yu He ◽  
Shuo Chen ◽  
Yingjian Tian ◽  
...  
Keyword(s):  
Stainless Steel ◽  
Austenitic Stainless Steel ◽  
Tool Wear ◽  
Surface Quality ◽  
Ultrasonic Vibration ◽  
Cutting Forces ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
304 Austenitic Stainless Steel ◽  
Machining System

The aim of this paper is to present an experimental investigation of the cutting forces, surface quality, tool wear and chip shape in ultrasonic vibration assisted turning (UAT) of 304 austenitic stainless steel (ASS 304) in comparison to conventional turning (CT). This study focuses on the solution of the machining difficulties of ASS 304 and high demands for the processing quality and efficiency. The machining system of UAT is schemed out to assure the desired machining effect by utilizing ultrasonic vibration method. Meanwhile, a series of systematic experiments are performed with and without ultrasonic vibration using the designed machining system of UAT with cemented carbide coated cutting tool. The results obtained from the UAT and CT experiments demonstrate that the cutting effect of UAT is much better than that of CT. Furthermore, the results of this research indicate that the ultrasonic amplitude, cutting speed, feed rate and depth of cut in UAT of ASS 304 have visible influence on the cutting forces, surface quality and tool wear. And reasonable selection of various technological variables in UAT can obtain lower cutting forces, more superior surface roughness, advantageous surface topography, slow and less tool wear, thin and smooth chips.

The Effect of One Directional Ultrasonic Vibration Assistance in High Speed Meso-Scale Milling Process

2010 ◽  
Vol 447-448 ◽  
pp. 41-45 ◽  
Author(s):  
Jeong Hoon Ko ◽  
Kah Chuan Shaw ◽  
Han Kwang Chua ◽  
Rong Ming Lin
Keyword(s):  
Surface Quality ◽  
Ultrasonic Vibration ◽  
High Speed ◽  
Cutting Speed ◽  
Milling Process ◽  
Air Bearing ◽  
Machined Surface ◽  
Machined Surface Quality ◽  
Milled Surface ◽  
Vibration Assistance

One-directional ultrasonic vibration assisted milling system is designed and its performance is investigated in terms of machined surface quality under 135,000 rpm. The ultrasonic vibration generator excites the workpiece with a frequency around 40 kHz and amplitude of a few micro meters. The milling tool’s cutting speed is controlled by an air-bearing spindle system. Both feed-directional and cross-feed directional ultrasonic vibration assistance are considered in order to understand the mechanism of ultrasonic vibration assistance for surface roughness generation. A comparison is done on a milled surface which is generated with and without ultrasonic vibration assistance. The experimental results show that ultrasonic vibration assistance can improve the machined surface quality which depended on the cutting edge radius and the feed per tooth.

Experimental Investigation on Hybrid Technology of Ultrasonic Vibration Assisted Chemo-Mechanical Grinding (CMG) Silicon Wafer

2013 ◽  
Vol 275-277 ◽  
pp. 2290-2294
Author(s):  
Wei Ping Yang ◽  
Yong Bo Wu ◽  
Jun Liu
Keyword(s):  
Surface Quality ◽  
Silicon Wafer ◽  
Ultrasonic Vibration ◽  
Substrate Surface ◽  
High Surface ◽  
Machining Process ◽  
Hybrid Technique ◽  
Mechanical Grinding ◽  
Vibration Assistance ◽  
Profile Accuracy

For the final finishing of the substrate surface, Chemo-mechanical polishing (CMP) is often utilized. Those processes are able to offer a great sur-face roughness, but sacrifice profile accuracy. On the other hand, Chemo-mechanical grinding (CMG) is potentially emerging defect-free machining process which combines the advantages of CMP. In order to simultaneously achieve high surface quality and high profile accuracy, CMG process has been applied into machining of large size quartz glass substrates for photomask use. In this paper, based on the characteristics of higher machining efficiency and higher surface quality of ultrasonic vibration machining, a new ultrasonic vibration assisted CMG of silicon wafer hybrid technique is achieved by designing elliptical vibrator with longitudinal mode and bending mode. The experimental results show that under the elliptic ultrasonic vibration assistance, the surface roughness is decreased significantly, the surface quality is improved obviously, and moreover caused little or even doesn’t lead to the surface damage.

Prediction of specific grinding forces and surface roughness in machining of AL6061-T6 alloy using ANFIS technique

2019 ◽  
Vol 71 (2) ◽  
pp. 309-317 ◽  
Author(s):  
Yusuf S. Dambatta ◽  
Mohd Sayuti ◽  
Ahmed A.D. Sarhan ◽  
Hamdi Bin Ab Shukor ◽  
Nur Aqilah binti Derahman ◽  
...  
Keyword(s):  
Surface Roughness ◽  
Surface Quality ◽  
Feed Rate ◽  
Tangential Force ◽  
Air Pressure ◽  
Depth Of Cut ◽  
Nanoparticle Concentration ◽  
Grinding Forces ◽  
Silicon Dioxide Nanoparticles ◽  
Content Type

Purpose Optimisation of grinding processes involves enhancing the surface quality and reducing the cost of manufacturing through reduction of power consumptions. Recent research works have indicated the minimum quantity lubrication (MQL) system is used to achieve near dry machining of alloys and hard materials. This study aims to provide an experimental analysis of the grinding process during machining of aluminium alloy (Al6061-T6). MQL nanofluid was used as the lubricant for the grinding operations. The lubricant was formed by suspending silicon dioxide nanoparticles in canola vegetable oil. The effect of input parameters (i.e. nanoparticle concentration, depth of cut, air pressure and feed rate) on the grinding forces and surface quality was studied. Adaptive neuro-fuzzy inference system (ANFIS) prediction modelling was used to predict the specific normal force, specific tangential force and surface quality, the ANFIS models were found to have prediction accuracies of 97.4, 96.6 and 98.5 per cent, respectively. Further study shows that both the specific grinding forces and surface roughness are inversely proportional to the nanofluid concentration. Also, the depth of cut and table feed rate were found to have a directly proportional relationship with both the grinding forces and surface roughness. Moreover, higher MQL air pressure was found to offer better delivery of the atomised nanofluid into the grinding region. Design/methodology/approach Grinding experiments were performed using MQL nanofluid as the lubricant. The lubricant was formed by suspending silicon dioxide nanoparticles in canola vegetable oil. The effect of input parameters (i.e. nanoparticle concentration, depth of cut, air pressure and feed rate) on the grinding forces and surface quality has been studied. Findings The grinding process parameters were optimised using Taguchi S/N ratio analysis, whereas the prediction of the response parameters was done using ANFIS modelling technique. The developed ANFIS models for predicting the specific normal force, specific tangential force and surface quality were found to have prediction accuracies of 97.4, 96.6 and 98.5 per cent, respectively. Further findings show that both the specific grinding forces and surface roughness are inversely proportional to the percentage of nanoparticle concentration in the lubricant. Also, the depth of cut and table feed rate were found to exhibit a direct proportional relationship with both the grinding forces and surface roughness, while high MQL air pressure was observed to offer more efficient delivery of the atomised nanofluid into the grinding region. Practical implications The work can applied into manufacturing industries to prevent unnecessary trials and material wastages. Originality/value The purpose of this study is to develop an artificial intelligent model for predicting the outcomes of MQL grinding of the aluminium alloy material using ANFIS modelling technique.

Modeling of High Efficiency Removal in the Grinding of Aluminal/ZrO2 Nanocomposites with the Aid of Two-Dimensional Ultrasonic Vibration

2007 ◽  
Vol 329 ◽  
pp. 451-458 ◽  
Author(s):  
Yan Wu ◽  
A.G. Sun ◽  
Bo Zhao ◽  
Xun Sheng Zhu
Keyword(s):  
Ultrasonic Vibration ◽  
Material Removal Rate ◽  
Material Removal ◽  
High Efficiency ◽  
Removal Rate ◽  
Abrasive Particle ◽  
Experimental Results ◽  
Two Dimensional ◽  
Conventional Grinding ◽  
Vibration Assistance

Based on the single abrasive particle motion locus of elliptical spiral in two-dimensional ultrasonic vibration grinding (WTDUVG), the theoretical model representing the material removal rate are deduced and verified, and the reason of high efficiency material removal by applying two-dimensional ultrasonic vibration is analyzed. Finally, experimental researches on material removal rate of ceramics were carried out using coarse grit diamond wheel both with and without workpiece two-dimensional ultrasonic vibration assistance grinding. Experimental results indicated that (1) Material removal rate (MRR) in vibration grinding process is about 1.5 times as large as that of in conventional grinding, the experimental results are in good agreement with the calculated ones. (2)The material removal rate increases along with increases of the grinding depth and workpiece velocity both in with and without vibration grinding. (3)The vibration grinding surface had no spur and build-up edge and its surface roughness was smaller than CG significantly. Surface quality of WTDUVG is superior to that of conventional grinding, it is easy for ultrasonic vibration grinding that material removal mechanism is ductile regime grinding.

Brittle-Ductile Transition in the Two-Dimensional Ultrasonic Vibration Grinding of Nanocomposite Ceramics

2009 ◽  
Vol 416 ◽  
pp. 477-481 ◽  
Author(s):  
Yan Wu ◽  
Bo Zhao ◽  
Xun Sheng Zhu
Keyword(s):  
Ultrasonic Vibration ◽  
Abrasive Particle ◽  
Depth Of Cut ◽  
Motion Model ◽  
Indentation Fracture ◽  
Brittle Ductile Transition ◽  
Transition Mechanism ◽  
Grinding Conditions ◽  
Critical Depth Of Cut ◽  
Micro Topography

Based on impulse theories and indentation fracture mechanics, the motion model of the contact between abrasive particle and workpiece in workpiece two-dimension ultrasonic vibration grinding (WTDUVG) was analyzed, and the critical condition of ultrasonic vibration grinding brittle-ductile transition was analyzed theoretically, furthermore the critical cutting depths of a grain under different grinding conditions were obtained by Matlab programs. In this work, the ultrasonic vibration and conventional diamond grinding of Al2O3/ZrO2 nanoceramics were performed in order to investigate the effect of workpiece ultrasonic vibration on the brittle-ductile transition mechanism, the effect of grit size, worktable speed and grinding depth on the critical depth of cut were studied by grinding experiments. the micro-topography of the grinding surface was observed by AFM and SEM. Experiment indicated that only when the grinding depth less than critical grinding depth, ductile regime grinding of ceramics can be realized, the appropriate grinding parameter on surface finish are suggested.

Tool Wear and Surface Roughness in Diamond Cutting of Die Steels

2013 ◽  
Vol 589-590 ◽  
pp. 227-231 ◽  
Author(s):  
Lai Zou ◽  
Guo Jun Dong ◽  
Ming Zhou
Keyword(s):  
Surface Roughness ◽  
Tool Wear ◽  
Surface Quality ◽  
Ultrasonic Vibration ◽  
Cutting Parameters ◽  
Experimental Investigations ◽  
Depth Of Cut ◽  
Machined Surface ◽  
Die Steels ◽  
Micro Morphology

This paper performed a series of experimental investigations for typical die steels with ultrasonic vibration assisted turning. The micro-morphology of rake face and flank face of diamond was detected by scanning electron microscopy, and the roughness of machined surface was measured by Form Talysurf. In order to clarify the influence laws of cutting parameters and tool geometric parameters on tool wear and surface quality. The results revealed that the wear of diamond and surface roughness rely heavily on the feed rate, and have less relativity with the relief angle and the depth of cut to an extent. In addition, the function mechanism of ultrasonic vibration turning had been analyzed, it exhibited that this technological measure has enhanced tool life and improved surface quality to a large extent.

Experimental Investigations of Grinding Forces in Elliptical Ultrasonic Assisted Grinding (EUAG) of Monocrystal Sapphire

2013 ◽  
Vol 797 ◽  
pp. 223-228
Author(s):  
Zhi Qiang Liang ◽  
Tian Feng Zhou ◽  
Xi Bin Wang ◽  
Yong Bo Wu ◽  
Wen Xiang Zhao
Keyword(s):  
Ultrasonic Vibration ◽  
Wheel Speed ◽  
Depth Of Cut ◽  
Grinding Wheel ◽  
Grinding Forces ◽  
Ultrasonic Assisted Grinding ◽  
Grinding Parameters ◽  
Force Ratio ◽  
Ultrasonic Assisted ◽  
Vibration Assistance

Grinding forces characteristics in elliptical ultrasonic assisted grinding (EUAG) of sapphire are investigated experimentally. The EUAG is a new grinding method proposed by the present authors in which an elliptical ultrasonic vibration is imposed on the workpiece by using an elliptical ultrasonic vibrator. In this paper, grinding experiments under the presence/absence of ultrasonic vibration assistance are performed. The effects of the vibration amplitude and grinding parameters such as the depth of cut, the grinding wheel speed on the grinding forces, grinding force ratioFn/Ftare clarified. The obtained conclusions are as follows: the grinding forces during EUAG lowers to 50% and grinding forces ratio becomes reduced by 33% compared that during conventional grinding (CG); the grinding forces during EUAG have the less variation rate than those during CG as grinding parameters change; higher grinding wheel speed causes the larger grinding forces in CG, but has little effect on the variation of grinding forces in EUAG. By using EUAG method, the grinding forces and force ratio are greatly decreased, and surface quality is better, meaning that grindability of sapphire material is improved.

Precise-Micro PECM System and its Applications Combining Synchronizing Ultrasonical Vibration

2011 ◽  
Vol 295-297 ◽  
pp. 834-839 ◽  
Author(s):  
Yong Wei Zhu ◽  
Xing Lei Miao ◽  
Chao Feng Zhang
Keyword(s):  
Surface Quality ◽  
Ultrasonic Vibration ◽  
Electrical Discharge Machining ◽  
New Technology ◽  
Electrochemical Machining ◽  
Electrical Circuit ◽  
Machining Accuracy ◽  
Machining Parameters ◽  
Micro Machining ◽  
High Productivity

The micro-PECM (Pulse Electrochemical Machining) combining synchronous ultrasonic vibration is proposed as a new technology for to solve the difficulty machining problems of conductive hard and tough materials. The feasibility of micro-PECM combining synchronous ultrasonic vibration is studied. The synchronous way is analyzed; the synchronous electrical circuit is designed and made. The synchronous electrochemical micro-machining system combining ultrasonical vibration are built and improved，which machining parameters can be adjusted in a wide ranges, and the synchronous target of the ultrasonical vibration with the voltage of micro-PECM can be realized. The micro-machining electrodes are manufactured in different sections and sizes by combined electrical discharge machining. The mechanism tests of micro-PECM are carried, which kentaniums （YBD151、YG8）and stainless steel are machined and the results are analyzed and discussed. Contrast with the single micro-USM, the micro-PECM combining ultrasonic vibration has high productivity, good machining accuracy and surface quality; furthermore, its cathode wastage is low. The micro-PECM combining synchronous ultrasonic vibration has the best machining precision and surface quality.

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