Enhancing the performance of polycrystalline diamond tools for machining WC by ultrasonic elliptical vibration cutting method

2009 ◽  
Vol 27 (3) ◽  
pp. 1241 ◽  
Author(s):  
Chandra Nath ◽  
Mustafizur Rahman ◽  
Ken Soon Neo
Keyword(s):  
Polycrystalline Diamond ◽  
Elliptical Vibration Cutting ◽  
Cutting Method ◽  
Vibration Cutting ◽  
Diamond Tools ◽  
Elliptical Vibration ◽  
Ultrasonic Elliptical Vibration

Ultrasonic Elliptical Vibration-Assisted Micro-Groove Turning

2014 ◽  
Vol 625 ◽  
pp. 603-606 ◽  
Author(s):  
Chen Zhang ◽  
Kornel Ehmann ◽  
Ying Guang Li ◽  
Ping Guo
Keyword(s):  
Cutting Forces ◽  
Burr Formation ◽  
Ultrasonic Frequency ◽  
Elliptical Vibration Cutting ◽  
Cutting Method ◽  
Vibration Cutting ◽  
Elliptical Vibration ◽  
Comparison Results ◽  
Series Of Experiments ◽  
Ultrasonic Elliptical Vibration

In ultrasonic vibration the cutting edge of a tool is vibrated in the principal or cutting direction, generally at a constant ultrasonic frequency. The main characteristic of this cutting method is its intermittent nature involving repeated cutting and pausing. In this paper, ultrasonic elliptical vibration cutting is used to assist micro-groove turning of cylindrical surfaces. The elliptical locus during the cutting process is generated by a newly designed 2D resonant ultrasonic vibrator. A series of experiments were performed to verify the effects of the ultrasonic elliptical vibrations. The generated cutting forces and burr formation were compared for the ordinary and the elliptical vibration-assisted cases. Comparison results show the effectiveness of the elliptical vibration cutting method in reducing cutting forces and alleviating burr formation.

Theoretical and Experimental Investigation on Inclined Ultrasonic Elliptical Vibration Cutting of Alumina Ceramics

2016 ◽  
Vol 138 (12) ◽  
Author(s):  
Wu-Le Zhu ◽  
Yu He ◽  
Kornel F. Ehmann ◽  
Antonio J. Sánchez Egea ◽  
Xinwei Wang ◽  
...  
Keyword(s):  
Cutting Forces ◽  
Removal Rate ◽  
Polycrystalline Diamond ◽  
Machining Parameters ◽  
Machined Surface ◽  
Pure Alumina ◽  
Elliptical Vibration Cutting ◽  
Vibration Cutting ◽  
Elliptical Vibration ◽  
Ultrasonic Elliptical Vibration

Alumina (Al2O3) is an extremely hard and brittle ceramic that is usually used as an abrasive or a cutting tool insert in manufacturing. However, its growing applications in industrial products make it necessary to conduct a study of the machinability of alumina themselves with a cost-effective and flexible method, rather than conventional diamond grinding or laser-assisted processing methods. In this paper, polycrystalline diamond tools are used to investigate the machining of nonporous pure alumina by applying an inclined ultrasonic elliptical vibration cutting (IUEVC) method. First, a theoretical analysis is presented to study the effects of the machining parameters on cutting performances during raster cutting procedures from the prospective of the material removal rate (MRR), tool-chip contact area, cutting edge angle, etc. Then, experiments are carried out to investigate the cutting forces and the areal surface roughness (Sa) in connection with the theoretically established relationships. The results show that the cutting forces are remarkably reduced, by up to more than 90%, and that the machined surface finish is also improved compared with conventional methods.

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.

Mirror Surface Machining of Steel by Elliptical Vibration Cutting with Diamond-Coated Tools Sharpened by Pulse Laser Grinding

2018 ◽  
Vol 12 (4) ◽  
pp. 573-581 ◽  
Author(s):  
Hiroshi Saito ◽  
Hongjin Jung ◽  
Eiji Shamoto ◽  
Shinya Suganuma ◽  
Fumihiro Itoigawa ◽  
...  
Keyword(s):  
Low Cost ◽  
Mirror Surface ◽  
Elliptical Vibration Cutting ◽  
Surface Machining ◽  
Vibration Cutting ◽  
Die Steel ◽  
Elliptical Vibration ◽  
Coated Tools ◽  
Ultrasonic Elliptical Vibration ◽  
Rapid Tool

Low-cost mirror surface machining of die steel is proposed in this research by applying elliptical vibration cutting with diamond-coated tools sharpened by pulse laser grinding (PLG). It is well known that conventional diamond cutting cannot be applied to die steel owing to rapid tool wear. Several attempts have been reported to prevent rapid tool wear, such as using ultrasonic elliptical vibration cutting. The ultrasonic elliptical vibration cutting developed by the authors to achieve mirror surface finish on die steel and prevent rapid wear is widely used in the industry. However, high-cost single-crystalline diamond tools that are finished using a time-consuming lapping process are required to obtain mirror surfaces. The authors, meanwhile, have recently developed the PLG process to efficiently sharpen the cutting edges of hard tool materials such as cubic boron nitride. Therefore, a practical mirror surface machining method for die steel is proposed in this research, namely elliptical vibration cutting with low-cost diamond-coated tools sharpened by the efficient PLG process. The results of the machining experiments confirmed that practical mirror surface machining of die steel can be achieved by the proposed method.

High Frequency Ultrasonic Elliptical Vibration Turning Studty for Weak Rigidity Precision Workpiece

2011 ◽  
Vol 467-469 ◽  
pp. 236-240 ◽  
Author(s):  
Wen Li ◽  
De Yuan Zhang
Keyword(s):  
Surface Roughness ◽  
High Frequency ◽  
Critical Speed ◽  
Machining Efficiency ◽  
Elliptical Vibration Cutting ◽  
Vibration Cutting ◽  
Elliptical Vibration ◽  
Forming Accuracy ◽  
Ultrasonic Elliptical Vibration ◽  
Cutting Direction

Based on analysis of the micro-surface and kinematical formulas of elliptical vibration cutting(EVC), the paper presents that frequency and amplitude of vibration parameter affect surface roughness, forming accuracy and machining efficiency of weak rigidity workpiece: increase vibration frequency are result in lower vibration cutting duty cycle , lower cutting force, advancer critical speed, so advance forming accuracy and machining efficiency; decrease amplitude are result in reduce the height of vibration ripples in cutting direction , so improve surface roughness. Experiences of cutting the weak rigidity workpiece by the designed double bending hybrid vibration high transducer, verified that the high frequency elliptical vibration cutting are proved more conducive to machining weak rigidity workpiece.

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