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TECHNICAL PAPERS

Contact Zone Force Profile and Machining Performance of Filamentary Brush

[+] Author and Article Information
R. J. Stango, V. Cariapa, M. Zuzanski

Department of Mechanical and Industrial Engineering, Marquette University, Milwaukee, WI 53233

J. Manuf. Sci. Eng 127(1), 217-226 (Mar 21, 2005) (10 pages) doi:10.1115/1.1861472 History: Received March 04, 2003; Revised February 18, 2004; Online March 21, 2005
Copyright © 2005 by ASME
Topics: Force , Machining , Wire
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References

FitzPatrick, P. R., and Paul, F. W., 1987, “Robotic Finishing Using Brushes—Material Removal Mechanics,” SME, Deburring and Surface Conditioning Conference, Phoenix, AZ, MR87-156.
Stango,  R. J., Cariapa,  V., Prasad,  A., and Liang,  S. K., 1991, “Measurement and Analysis of Brushing Tool Performance Characteristics—Part I: Stiffness Response,” ASME J. Eng. Ind., 113(3), pp. 283–289.
Cariapa,  V., Stango,  R. J., Liang,  S. K., and Prasad,  A., 1991, “Measurement and Analysis of Brushing Tool Performance Characteristics—Part II: Contact Zone Geometry,” ASME J. Eng. Ind., 113(3), pp. 290–296.
Stango,  R. J., Heinrich,  S. M., and Shia,  C. Y., 1989, “Analysis of Constrained Filament Deformation and Stiffness Properties of Brushes,” ASME J. Eng. Ind., 111(3), pp. 238–243.
Shia,  C. Y., and Stango,  R. J., 1994, “On the Frictional Response of Circular Filamentary Brush in Contact With Planar Workpart,” Int. J. Mach. Tools Manuf., 34(4), pp. 573–589.
Shia,  C. Y., Stango,  R. J., and Heinrich,  S. M. 1998, “Analysis of Contact Mechanics for a Circular Filamentary Brush/Workpart System: Solution Method and Numerical Studies,” ASME J. Manuf. Science and Engineering,120(4), pp. 715–721.
Hatman,  V. G., Haque,  I., and Bagchi,  A., 1996, “Dynamics of a Flexible Rotating Beam Interacting With a Flat Rigid Surface—Part I: Model Development,” J. Sound Vib., 194(5), pp. 653–669; and “Part II: Numerical Solution,” 194(5), pp. 671–683.
Cariapa,  V., Stango,  R. J., Chen,  L., and Hermann,  R., 1992, “Aspects of Process Model for Automatic Control of Edge Deburring With Filamentary Brush,” ASME J. Eng. Ind., 114(3), pp. 294–300.
Stango,  R. J., Chen,  L., and Cariapa,  V., 1999, “Automated Deburring With Filamentary Brush: Prescribed Burr Geometry,” ASME J. Manuf. Sci. Eng., 121(3), pp. 385–392.
Chen,  L., Stango,  R. J., and Cariapa,  V., 2001, “Development of Force-Control Model for Edge-Deburring With Filamentary Brush,” ASME J. Manuf. Sci. Eng., 123(3), pp. 528–532.
Tarrab, K., 1990, “Dynamic Properties of Circular Brushes and Evaluation of Filamentary Stress: Photographic Analysis,” M.S. thesis, Marquette University, Milwaukee, WI.
Popken, J. L., 1990, “Three-Dimensional Topology of Plates Generated by Circular Brushing Tools,” M.S. thesis, Marquette University, Milwaukee, WI.

Figures

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(a) Illustration of circular filamentary brush and flat workpart depicting standard geometry and resultant force F exerted by workpart onto brush; (b) crimped filament of diameter d; and (c) resultant filament force exerted by workpart onto fiber tip
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(a) Side view of wire filament in contact with flat workpart surface, and (b) top view of brushed surface depicting filament tip score markings and geometry/nomenclature of contact zone
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Experimental system used for measurement of contact zone force. Shaded surface and dashed-line underbody represents position of three-axis force sensor
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(a) Side view of brush/workpart system; (b) hypothetical force profile (top) and force profile gradient (bottom); and (c) illustration of discrete filament forces within two successive subregion intervals
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(a) Normal force and (b) shear force obtained for wire brush using active contact width of 6.25 mm (0.25 in.), penetration depth of 2.54 mm (0.1 in.), and brush rotational speed of 550 rpm
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Summary of resultant brush force using various active brush widths (W* ) at three different rotational speeds: 550, 1300, and 2850 rpm
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Acquired longitudinal force profile for (a) normal force and (b) shear force using active brush width 12.5 mm (0.5 in.), penetration depth 2.5 mm (0.1 in.), and brush rotational speed of 550 rpm
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Reconstruction of longitudinal normal force profile contact event using active brush width 12.5 mm (0.5 in.), penetration depth 2.5 mm (0.1 in.) at brush rotational speeds of 550, 1300, and 2850 rpm
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Friction coefficient (quotient of shear/normal contact zone force profile) along length coordinate s for (a) 550 rpm; (b) 1300 rpm; and (c) 2850 rpm
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Gradient of contact zone force profile for acquire force data at 550, 1300, and 1850 rpm. Results are for penetration depth 2.5 mm (0.1 in.), and active brush width 12.5 mm (0.5 in.).
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Material removal profile along longitudinal centerline of contact zone (6061-T6 AI) for 300 contact revolutions of wire brush at penetration depth of 19.05 mm (0.7 in.)

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