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Research Papers

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 100084, China;
Department of Mechanical and
Automation Engineering,
The Chinese University of Hong Kong,
Hong Kong 999077, China

Jianfu Zhang, Qiaoli Zhang

State Key Laboratory of Tribology,
Tsinghua University,
Beijing 100084, China

Pingfa Feng

State Key Laboratory of Tribology,
Tsinghua University,
Beijing 100084, China;
Division of Advanced Manufacturing,
Graduate School at Shenzhen,
Tsinghua University,
Shenzhen 518055, China

Ping Guo

Department of Mechanical and
Automation Engineering,
The Chinese University of Hong Kong,
Hong Kong 999077, China

1Corresponding author.

Manuscript received July 6, 2017; final manuscript received November 29, 2017; published online March 6, 2018. Assoc. Editor: Guillaume Fromentin.

J. Manuf. Sci. Eng 140(5), 051008 (Mar 06, 2018) (11 pages) Paper No: MANU-17-1408; doi: 10.1115/1.4038728 History: Received July 06, 2017; Revised November 29, 2017

In order to further improve the processing performance of rotary ultrasonic machining (RUM), a novel longitudinal–torsional-coupled (LTC) vibration was applied to the RUM. An experimental study on quartz glass was performed to access the feasibility of the LTC-RUM of a brittle material. The LTC-RUM was executed through the addition of helical flutes on the tool of conventional longitudinal RUM (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 an average, compared to the Con-RUM. Moreover, the LTC-RUM could also improve the quality of the hole wall through the reduction of surface roughness, in particular, when the spindle speed was relatively low. The mechanism of superior processing performance of LTC-RUM involved the corresponding specific moving trajectory of diamond abrasives, along with higher lengths of lateral cracks produced during 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 increase in the maximum cutting speed. Furthermore, the effect of spindle speed on the cutting force and surface roughness variations verified the important role of the moving trajectory of the diamond abrasive in the superior processing performance mechanism of LTC-RUM.

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Figures

Grahic Jump Location
Fig. 1

Illustration of RUM

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Fig. 2

Kinematic view of LTC-RUM: (a) definition of coordinate, (b) amplitude comparison of LTC-RUM and Con-RUM, and (c) moving trajectory of diamond abrasives

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Fig. 3

Experimental setup

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Fig. 4

Tool design: (a) dimension of helical flutes, (b) meshing result of FEA, (c) loading regime of FEA, and (d) simulation result of FEA

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Fig. 5

Effect of ultrasonic frequency on amplitude ratio and phase difference between torsional vibration and longitudinal vibration

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Fig. 6

Two types of experiments: (a) blind hole drilling and (b) through hole drilling

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Fig. 7

Calculation of average cutting force Fc

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Fig. 8

Representation of edge chipping size

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Fig. 9

Method for the measurement of roughness of hole surface

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Fig. 10

Effect of processing parameters on edge chipping size at hole entrance

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Fig. 11

Edge chipping at hole entrance: (a) crack system produced by diamond abrasives indentation on workpiece material, (b) formation mechanism of edge chipping at hole entrance [49], and (c) serrated morphology of edge chipping at hole entrance

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Fig. 12

Effect of processing parameters on cutting force

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Fig. 13

Analysis of cutting force calculation: (a) Con-RUM and (b) LTC-RUM

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Fig. 14

Comparison of edge chipping sizes at hole exit

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Fig. 15

Comparison of surface roughness of hole wall

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