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research-article

Feasibility study of longitudinal-torsional coupled rotary ultrasonic machining of brittle material

[+] Author and Article Information
Jianjian Wang

State Key Laboratory of Tribology, Tsinghua University, Beijing, China; Department of Mechanical and Automation Engineering, the Chinese University of Hong Kong, Hong Kong, China
wangjj11@outlook.com

Jianfu Zhang

State Key Laboratory of Tribology, Tsinghua University, Beijing, China
zhjf@mail.tsinghua.edu.cn

Pingfa Feng

State Key Laboratory of Tribology, Tsinghua University, Beijing, China; Division of Advanced Manufacturing, Graduate School at Shenzhen, Tsinghua University, Shenzhen, China
wangjj11@foxmail.com

Ping Guo

Department of Mechanical and Automation Engineering, the Chinese University of Hong Kong, Hong Kong, China
pguo@mae.cuhk.edu.hk

Qiaoli Zhang

State Key Laboratory of Tribology, Tsinghua University, Beijing, China
843024770@qq.com

1Corresponding author.

ASME doi:10.1115/1.4038728 History: Received July 06, 2017; Revised November 29, 2017

Abstract

In order to further improve the processing performance of rotary ultrasonic machining (RUM), a novel longitudinal-torsional coupled vibration was applied to the RUM. An experimental study on quartz glass was performed to access the longitudinal-torsional coupled rotary ultrasonic machining (LTC-RUM) feasibility of a brittle material. The LTC-RUM was executed through the helical flutes addition on the tool of conventional longitudinal rotary ultrasonic machining (Con-RUM). The experimental results demonstrated that the LTC-RUM could reduce the cutting force by 55% and the edge chipping size at the hole exit by 45% on average, compared to the Con-RUM. Also, the LTC-RUM could improve the hole wall quality through the surface roughness reduction, especially when the spindle speed was relatively low. The mechanism of superior processing performance of LTC-RUM was the corresponding specific moving trajectory of diamond abrasives, along with the higher lengths of lateral cracks that produced in the abrasives indentation on the workpiece material. The higher edge chipping size at the hole entrance of LTC-RUM indicated a higher length of lateral cracks in LTC-RUM, due to the maximum cutting speed increase. In addition, the effect of spindle speed on the cutting force and surface roughness variations verified the moving trajectory important role of the diamond abrasive in the superior processing performance mechanism of LTC-RUM.

Copyright (c) 2017 by ASME
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