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Research Papers

Dynamic Process Modeling for Rotary Ultrasonic Machining of Alumina

[+] Author and Article Information
Jiaqing Wu

Department of Industrial and Management Systems Engineering,  University of Nebraska-Lincoln, W348B NH, Lincoln, NE 68588-0518wujiaqing@huskers.unl.edu

Weilong Cong

Department of Industrial and Manufacturing Systems Engineering,  Kansas State University, 2037 Durland Hall, Manhattan, KS 66506-5101weilong@ksu.edu

Robert E. Williams

Department of Mechanical and Materials Engineering,  University of Nebraska-Lincoln, W348B NH, Lincoln, NE 68588-0518rwilliams2@unl.edu

Z. J. Pei

Department of Industrial and Manufacturing Systems Engineering,  Kansas State University, 2011 Durland Hall, Manhattan, KS 66506-5101zpei@ksu.edu

J. Manuf. Sci. Eng 133(4), 041012 (Aug 11, 2011) (5 pages) doi:10.1115/1.4004688 History: Received February 07, 2011; Revised July 18, 2011; Published August 11, 2011; Online August 11, 2011

Rotary ultrasonic machining (RUM) is a hybrid machining approach that combines two material removal mechanisms, namely, diamond grinding and ultrasonic machining. This paper presents the results of dynamic process modeling for RUM of alumina, as currently available literature mainly focuses on static parametric relationships. A stochastic modeling and analysis technique called data dependent systems (DDS) was used to study RUM generated surface profiles and cutting force signals. Variations in the data sets of surface profiles, for the entrance and exit segments of machined holes and for that of machined rods, and cutting force signals were modeled and decomposed to gain insight into the RUM process mechanism. The DDS wavelength decomposition of the surface profiles suggested that the major characteristic root wavelength had a positive correlation with feed rate, and the wavelength magnitude may be linked to the grain size of the workpiece material. The roughness of machined surfaces increased as the tool moved deeper due to reduced flushing efficiency. Surfaces on the machined rods were less sensitive to the input variables than the hole surfaces. Moreover, spindle speed and feed rate affected the cutting force significantly.

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Copyright © 2011 by American Society of Mechanical Engineers
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Figures

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Figure 1

Illustration of rotary ultrasonic machining [3]

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Figure 2

Experimental setup of RUM

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Figure 3

Illustration of the hole and rod machined by RUM

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Figure 4

Measurement of maximum cutting force and average cutting force

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Figure 5

Main effects on Ra of machined holes

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