Article
Acoustics
Yunze Li, Dongzhe Zhang, Hui Wang, Gaihua Ye, Rui He, Weilong Cong
Summary: Brittle materials are widely used in various industries, and there is a growing demand for high-precision micro-machining of these materials. Traditional ultra-precision micro-machining can lead to issues such as workpiece cracking and low surface quality. Rotary ultrasonic machining is a nontraditional process that can effectively address these problems. This study investigates the effects of ultrasonic vibration and input parameters on cutting force and surface quality in micro-machining of brittle materials.
ULTRASONICS SONOCHEMISTRY
(2022)
Article
Materials Science, Ceramics
Fan Chen, Wenbo Bie, Xiaobo Wang, Bo Zhao
Summary: This study utilized the longitudinal-torsional coupled rotary ultrasonic machining technique to process ZrO2 ceramics and conducted experiments to investigate its effects. The results showed that this machining method significantly reduced cutting force and surface roughness, improved hole surface quality, and reduced abrasive particle wear.
CERAMICS INTERNATIONAL
(2022)
Article
Computer Science, Information Systems
Heng Zhao, Shuyuan Ye, Jianzhong Ju, Zhili Long, Yuhui Yang
Summary: This paper developed a novel heat shrinkable RUM ultrasonic transducer with a working frequency of 60 kHz using an equivalent circuit and finite element method. Three flange mounting structures were proposed to optimize energy transmission at the working resonant frequency. The experimental results showed good consistency with the theoretical calculations, demonstrating the effectiveness of the proposed design.
Article
Automation & Control Systems
Guoyan Sun, Feng Shi, Bowen Zhang, Qingliang Zhao, Wanli Zhang, Yongjie Wang, Ye Tian
Summary: A major challenge in manufacturing large-aperture aspheric optical components of glass ceramics is the long processing time. Ultrasonic vibration-assisted grinding (UVG) can greatly reduce the subsequent polishing process, but the surface creation mechanism of UVG-treated glass ceramics is not well-studied. This study investigates the surface formation mechanism of UVG-processed ceramics using two UVG methods: rotary ultrasonic vibration-assisted vertical grinding (RUVG) and parallel grinding (RUPG). The results show that RUVG is more suitable for high precision and efficiency grinding of aspheric surfaces compared to RUPG.
INTERNATIONAL JOURNAL OF ADVANCED MANUFACTURING TECHNOLOGY
(2023)
Article
Chemistry, Physical
T. G. Mamatha, Mohit Vishnoi, Siddharth Srivastava, Vansh Malik, Mudit K. Bhatnagar
Summary: In this study, Rotary Ultrasonic machining was used to fabricate micro channels on a Silicon wafer. By optimizing the machining parameters, the efficiency and performance of the machining process were improved.
Article
Engineering, Mechanical
Sandeep Kumar, Akshay Dvivedi, Tanmay Tiwari, Maneesh Tewari
Summary: A predictive model of tool wear in rotary tool micro-ultrasonic machining (RTMUSM) process using artificial intelligence has been reported for the first time. The model was developed using an adaptive neuro-fuzzy inference system (ANFIS) and artificial neural network (ANN) approaches. Six input process parameters were selected with the total volumetric wear (TVW) of the tool as the output data. The developed ANFIS model showed superior performance compared to the ANN model and can be used to measure tool wear in RTMUSM.
PROCEEDINGS OF THE INSTITUTION OF MECHANICAL ENGINEERS PART E-JOURNAL OF PROCESS MECHANICAL ENGINEERING
(2023)
Article
Automation & Control Systems
Fan Chen, Wenbo Bie, Yingli Chang, Bo Zhao, Xiaobo Wang, Yuemin Zhang
Summary: This study introduces a LTC-RUM cutting force model for zirconia ceramics based on the brittle material removal mechanism, and experimentally verifies the closely correlated results with the predicted cutting forces. The maximum discrepancies between the predicted and experimental cutting forces vary with different processing parameters. This research is important for predicting and optimizing the effects of processing parameters on the cutting force during LTC-RUM of ceramics.
INTERNATIONAL JOURNAL OF ADVANCED MANUFACTURING TECHNOLOGY
(2022)
Article
Engineering, Electrical & Electronic
Yue Chen, Zhongwei Hu, Yiqing Yu, Zhiyuan Lai, Jiegang Zhu, Xipeng Xu, Qing Peng
Summary: This study investigated the processing and mechanism of machining sapphire using ultrasonic vibration-assisted grinding technology. The effects of machining factors on machined surface, specific grinding energy, force and force ratio were analyzed. The application of ultrasonic vibration reduced force, force ratio, and specific energy, with the reduction ratio being direction dependent. It also had an anisotropic effect on surface roughness and morphology.
MATERIALS SCIENCE IN SEMICONDUCTOR PROCESSING
(2022)
Article
Mechanics
Longxu Yao, Zhanqiang Liu, Qinghua Song, Bing Wang, Yukui Cai
Summary: This study developed a prediction model for the axial and transverse grinding force components in rotary ultrasonic end grinding (RUEG) of SiO2f/SiO2 ceramic matrix composites. The model was validated by experimental results and the influence mechanism of process parameters on the grinding force components was explained.
COMPOSITE STRUCTURES
(2023)
Article
Engineering, Manufacturing
Iqbal Shareef, Julia Bjerke, Wasiq A. M. Abdul, Dennis Kroll
Summary: The study investigates the impact of rotary ultrasonic machining parameters on process outputs such as cutting force, surface roughness, and surface compressive residual stresses. The results indicate that using a larger grit size decreases the tool axial force, while samples with rougher surface finish exhibit higher surface residual compressive stresses. Surface residual compressive stresses are present regardless of the machining direction.
MANUFACTURING LETTERS
(2022)
Article
Engineering, Mechanical
Tian Lan, Pingfa Feng, Jianfu Zhang, Huilin Zhou, Jianjian Wang
Summary: Rotary ultrasonic machining (RUM) is an effective method for processing difficult-to-cut materials, but the understanding of critical cutting force in RUM system with frequency-tracking module is lacking. This study models the dependency of ultrasonic amplitude on cutting force and develops experimental methods to measure the actual ultrasonic amplitude and critical cutting force. The experimental results validate the models and analyze the influence of electrical and mechanical design on critical cutting force in frequency-tracked RUM system.
INTERNATIONAL JOURNAL OF MECHANICAL SCIENCES
(2023)
Article
Automation & Control Systems
Lukas Steinhoff, Rico Ottermann, Folke Dencker, Marc Christopher Wurz
Summary: Precision machining is becoming more important as the demand for higher surface quality increases. A study demonstrated a process strategy for finishing copper surfaces using batch-manufactured micro-grinding tools in an electrochemically assisted grinding process. By using finer abrasives grains and an optimized grinding process, similar or better surface roughness values could be achieved. The combination of the shown grinding process and anodic oxidation seems promising for achieving high surface finishes.
INTERNATIONAL JOURNAL OF ADVANCED MANUFACTURING TECHNOLOGY
(2023)
Article
Automation & Control Systems
Wenbo Bie, Fan Chen, Xiaobo Wang, Shaopeng Chen, Zongxia Fu, Bo Zhao
Summary: This study proposed a cutting force model for LTC-RUM end surface grinding of SiCf/SiC composites by analyzing the motion path and material removal mechanism of a single abrasive grain. The developed model was verified through experiments and showed non-linear decline of cutting force in LTC-RUM.
INTERNATIONAL JOURNAL OF ADVANCED MANUFACTURING TECHNOLOGY
(2023)
Article
Automation & Control Systems
Yi-Jia Sun, Zhen Chen, Sheng-Jun Ao, Hu Gong, Shu-Yu Gui
Summary: This study investigates the electrical characteristics of the ultrasonic vibration unit in a rotary ultrasonic machining (RUM) system. The relationship between electrical parameters and the resonant frequency of the ultrasonic vibration unit is studied when different tools are clamped. Rotary ultrasonic drilling experiments are conducted to study the effect of processing parameters on the electrical characteristics of the ultrasonic vibration unit. It is found that the variations of electrical parameters are significant under different ultrasonic voltages but not under different feed rates.
INTERNATIONAL JOURNAL OF ADVANCED MANUFACTURING TECHNOLOGY
(2023)
Article
Engineering, Electrical & Electronic
Jiaying Han, Yiqi Jiang, Xinrui Li, Qing Li
Summary: The rotating ultrasonic-assisted grinding (RUAG) experiment introduced intermittent pit-shaped micro-texture on the workpiece surface, reducing thermal damage and improving lubrication compared to conventional grinding (CG). This study aimed to understand the formation mechanism of micro-texture by establishing a mathematical equation for grinding depth based on the theory of micro-debris volume. Response surface analysis was conducted to analyze the relationships between macroscopic grinding depth, micro-texture feature parameters, and machining parameters. Single-factor experiments and simulations verified the theoretical micro-texture features.
