TY - JOUR
T1 - The effects of elliptical ultrasonic vibration in surface machining of CFRP composites using rotary ultrasonic machining
AU - Wang, Hui
AU - Zhang, Dongzhe
AU - Li, Yunze
AU - Cong, Weilong
N1 - Funding Information:
The U.S. National Science Foundation provided support (Grant No. CMMI-1538381).
Publisher Copyright:
© 2020, Springer-Verlag London Ltd., part of Springer Nature.
PY - 2020/2/1
Y1 - 2020/2/1
N2 - Compared with conventional surface grinding (CSG) process, surface machining of carbon fiber-reinforced plastic (CFRP) composites using rotary ultrasonic machining (RUM) with vertical ultrasonic vibration generates smaller cutting forces because of improved machining performance and more damages to the machined CFRP surface due to the intermittent knocking induced by vertical ultrasonic vibration. It is reported that surface quality can be improved when the ultrasonic vibration is parallel to the feeding direction. In addition, elliptical ultrasonic vibration can be formed by the combination of horizontal and vertical ultrasonic vibrations. However, the effects of elliptical ultrasonic vibration in RUM surface machining of CFRPs are still unknown. This paper will study the influences of elliptical ultrasonic vibration on the machining performance and machined surface quality in RUM surface machining of CFRPs. The comparisons of output variables (including cutting forces, surface roughness, and machined surface topography) between RUM surface machining with elliptical ultrasonic vibration and the CSG process as well as RUM surface machining with vertical ultrasonic vibration will be conducted under different levels of input variables (including depth of cut, feedrate, and tool rotation speed). The abrasive-grain trajectory and the tool-workpiece contacting modes in these three machining processes are analyzed. It is found that RUM surface machining with elliptical ultrasonic vibration produced smallest feeding-direction cutting force, smallest vertical-direction cutting force, best morphology of machined surface, and smallest surface roughness among these three kinds of machining processes.
AB - Compared with conventional surface grinding (CSG) process, surface machining of carbon fiber-reinforced plastic (CFRP) composites using rotary ultrasonic machining (RUM) with vertical ultrasonic vibration generates smaller cutting forces because of improved machining performance and more damages to the machined CFRP surface due to the intermittent knocking induced by vertical ultrasonic vibration. It is reported that surface quality can be improved when the ultrasonic vibration is parallel to the feeding direction. In addition, elliptical ultrasonic vibration can be formed by the combination of horizontal and vertical ultrasonic vibrations. However, the effects of elliptical ultrasonic vibration in RUM surface machining of CFRPs are still unknown. This paper will study the influences of elliptical ultrasonic vibration on the machining performance and machined surface quality in RUM surface machining of CFRPs. The comparisons of output variables (including cutting forces, surface roughness, and machined surface topography) between RUM surface machining with elliptical ultrasonic vibration and the CSG process as well as RUM surface machining with vertical ultrasonic vibration will be conducted under different levels of input variables (including depth of cut, feedrate, and tool rotation speed). The abrasive-grain trajectory and the tool-workpiece contacting modes in these three machining processes are analyzed. It is found that RUM surface machining with elliptical ultrasonic vibration produced smallest feeding-direction cutting force, smallest vertical-direction cutting force, best morphology of machined surface, and smallest surface roughness among these three kinds of machining processes.
KW - CFRP composite
KW - Cutting force
KW - Elliptical ultrasonic vibration
KW - Rotary ultrasonic machining
KW - Surface machining
KW - Surface quality
UR - http://www.scopus.com/inward/record.url?scp=85079429951&partnerID=8YFLogxK
U2 - 10.1007/s00170-020-04976-w
DO - 10.1007/s00170-020-04976-w
M3 - Article
AN - SCOPUS:85079429951
VL - 106
SP - 5527
EP - 5538
JO - International Journal of Advanced Manufacturing Technology
JF - International Journal of Advanced Manufacturing Technology
SN - 0268-3768
IS - 11-12
ER -