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Cutting force diagram of conventional orthogonal cutting (left) and vibration-assisted orthogonal cutting (right)
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![Types of vibration-assisted machining [9]](publication/356642653/figure/fig1/AS:1126112235134978@1645497487525/Types-of-vibration-assisted-machining-9_Q320.jpg)
![Position of the cutting edge in cutting direction [9]](publication/356642653/figure/fig3/AS:1126112235130883@1645497487585/Position-of-the-cutting-edge-in-cutting-direction-9_Q320.jpg)
To meet the modern demands for lightweight construction and energy efficiency, hard-to-machine materials such as ceramics, superalloys, and fiber-reinforced plastics are being used progressively. These materials can only be machined with great effort using conventional machining processes due to the high cutting forces, poor surface qualities, and...
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Composite manufacturing with multiple energy fields is an important source of processing technology innovation. In this work, comparative experiments on the conventional grinding (CG) and ultrasonic vibration-assisted grinding (UVAG) of hardened GCr15 steel were conducted with WA wheel. The grinding wheel wear patterns and chips were characterized....
Citations
... Besides, the friction between the cutting tool and the workpiece is significantly impacted by the addition of ultrasonic vibration. In order to calculate the force in both intermittent and non-intermittent cutting operations, Rinck et al. [19] proposed a force model that took into account the relative contact ratio extended macroscopic friction reduction. Sun et al. [20] developed a force model for rotary ultrasonic vibration-assisted side milling that incorporated the reduction in the friction coefficient to predict the decrease in cutting force. ...
Ultrasonic vibration–assisted machining represents a sophisticated manufacturing technique that offers several significant advantages, such as diminished tool wear and reduced cutting forces when processing hard-to-machine materials. Recent studies have extensively explored the generation and mechanisms of cutting forces in ultrasonic vibration–assisted machining from multiple perspectives. In situ TiB2/Al metal matrix composites have shown excellent performance in the field of aerospace engines, with a broad application prospect. However, its processing problems have always been a major obstacle to its application development. This study investigated the mechanisms underlying the cutting force generated during ultrasonic vibration–assisted cutting. Kinematic analysis was employed to examine the frictional interactions between the chip and the rake face. It indicates that ultrasonic vibrations exert a substantial influence on frictional behavior. Throughout a complete vibration cycle, the frictional process could be categorized into three distinct phases: the dynamic friction zone, the reverse dynamic friction zone, and the static friction zone. Furthermore, an analytical model of an orthogonal cutting force was developed with consideration of the transient shear angle and the friction reversal. Subsequently, a two-dimensional model was developed utilizing the finite-element simulation method to validate the accuracy of the cutting force model. The results showed that there was a certain degree of error between the theoretical predicted values and the output of the simulation model, and the error was less than 20%. Nevertheless, the observed trend in cutting force variations demonstrated a strong consistency between the two methods.
... 29,30 Furthermore, the bone LTVUM reduces the effects of bone anisotropy and cutting speed, while enhancing the impacts of feed rate. 29 Rinck et al. 31,32 found that the Ti-6Al-4V of LTVUM significantly reduces cutting force, improves cutting surface smoothness, and it has a better cutting performance compared to longitudinal assisted milling. Besides, Niu et al. 33 investigated the tool edge trajectory and cutting force of LTVUM, and reported that the cutting forces of the x and y directions decreased by 24.8% and 29.9%, respectively. ...
Multi-tooth milling cutters have the advantages of minimal surface damages and low cutting forces and are widely used in composite materials milling such as carbon fiber and wood. Cortical bone is a composite biomaterial similar to carbon fiber and wood; however, the cutting performance of multi-tooth milling cutters on bone cutting is unclear. Here, this paper proposes a multi-tooth milling cutter longitudinal torsional ultrasonic vibration assisted milling (LTVUM) method for cortical bone low damage cutting. The cutting performance of sinusoidal and corn edge cutters for cortical bone LTVUM was studied, and its material removal mechanisms were also established. The results indicated that the multi-tooth milling cutter has a smaller average cutting force, and suppressing the chip burrs and tearing damages. Compared to straight edge cutter, the resultant cutting forces of sinusoidal and corn edge cutters are decreased by 52.58%–61.01% and 45.60%−65.96%. The reason is that the secondary cutting edge of multi-tooth cutter can participate in cutting, reducing the tool squeeze interference. This work provides experimental guidance for the application of multi-tooth milling cutters LTVUM in bone cutting.
... In the X-UVAM, the tool-workpiece separation occurs in the feed direction, creating a gap between the cutting tool and the workpiece while maintaining contact with the slot bottom. The tool's flank face still maintains contact with the workpiece, preventing a complete halt in cutting and thereby resulting in the generation of frictional forces [32]. Finally, in Fig. 1 (d), the cutting tool tip motion of the XZ-UVAM with vibrations applied in a multi-axial direction can be seen. ...
Ti-6Al-4V offers a balance of good strength with lightweight properties. Yet, Ti-6Al-4V poses machining challenges, including low thermal conductivity, chemical adhesion to cutting tools, and chip removal difficulties. To improve machining efficiency, Ultrasonic Vibration-Assisted Machining (UVAM) has emerged as a promising approach. UVAM has demonstrated reduced tool wear, cutting forces, and improved surface quality compared to Conventional Machining (CM). Additionally, Minimum Quantity Lubrication (MQL) methods offer sustainable coolant alternatives, with recent research focusing on Nanofluid-MQL (NMQL) and Hybrid Nanofluid-MQL (HNMQL) for enhanced performance. Although there exists a body of literature showcasing the promising effects of UVAM and MQL methods individually, comprehensive investigations into the synergistic effects of these methodologies remain limited. This study addresses these critical research gaps by conducting a systematic examination of combined application of multi-axial UVAM and HNMQL. Specifically, it delves into the comparison of different vibration directions within UVAM, evaluates the effectiveness of UVAM when combined with cutting fluids incorporating Al2O3 and CuO nanoparticles in NMQLs and HNMQLs, and contrasts these novel approaches with conventional machining methods. The study unfolds in three distinct stages. The first stage examines the ultrasonic cutting mechanism and its combined application with the MQL technique. In the second stage, the study investigates the physical properties of the cutting fluids, including contact angle and surface tension. The final stage encompasses slot milling operations, where an array of parameters such as cutting forces, surface roughness, surface topography, surface texture, and the occurrence of burr formations are rigorously analyzed. The results demonstrate that the combination of multi-axial UVAM with HNMQL yields substantial advantages over traditional machining methods. Notably, it leads to a remarkable reduction in cutting forces (up to 37.6 %) and surface roughness (up to 37.4 %). Additionally, this combination engenders the production of highly homogeneous and uniform surface textures, characterized by minimal surface defects and a significantly diminished occurrence of burr formations. These findings underscore the potential of multi-axial UVAM combined with HNMQL as a promising approach in enhancing the machining of Ti-6Al-4V, thus offering a pathway to enhance the efficiency and precision of aerospace component manufacturing processes.
... In addition, vibration helps to remove chips from the milling zone and prevent their re-engagement, which results in a reduction in cutting forces, tool wear, and burr formation. As a result, the material undergoes a change in its physical properties and becomes softer or more pliable, allowing for smoother cutting and improved surface finishes 55,56 . However, the significance of thermal softening compared to dislocation activation depends on the material properties and machining parameters. ...
While cutting fluids are widely used in industrial mechanical machining of difficult-to-cut materials, achieving environmentally-friendly dry milling without the usage of cutting fluids by utilizing advanced manufacturing techniques makes significant sense for facilitating cleaner production. In the present work, we demonstrate the feasibility of enhancing dry machinability of TC4 titanium alloy by applying the newly proposed longitudinal-bending hybrid ultrasonic vibration-assisted milling (LBVAM), which is effective in modulating the intermittent cutting behavior between tool and material. Specifically, the kinematics and the material removal mechanisms of the LBVAM are investigated by analytical investigation, 3D finite element simulations and corresponding experiments. Simulation and experimental results demonstrate that the utilization of LBVAM enables lowering the surface roughness by 46.7% and reducing the cutting force by 43.2% from conventional milling. And the mostly prominent feature is that the surface roughness can be down to 100 nm by using the proposed LBVAM with rationally selected parameters, which is highly promising for realizing cleaner dry manufacturing of TC4 without using cutting fluids. Current work provides a feasible environmentally-friendly machining method for enhancing the dry machinability of difficult-to-cut materials.
