Vibration characteristics and machining performance of a novel perforated ultrasonic vibration platform in the grinding of particulate-reinforced titanium matrix composites
Received date: 01 May 2022
Accepted date: 31 Jul 2022
Copyright
Ultrasonic vibration-assisted grinding (UVAG) is an advanced hybrid process for the precision machining of difficult-to-cut materials. The resonator is a critical part of the UVAG system. Its performance considerably influences the vibration amplitude and resonant frequency. In this work, a novel perforated ultrasonic vibration platform resonator was developed for UVAG. The holes were evenly arranged at the top and side surfaces of the vibration platform to improve the vibration characteristics. A modified apparent elasticity method (AEM) was proposed to reveal the influence of holes on the vibration mode. The performance of the vibration platform was evaluated by the vibration tests and UVAG experiments of particulate-reinforced titanium matrix composites. Results indicate that the reasonable distribution of holes helps improve the resonant frequency and vibration mode. The modified AEM, the finite element method, and the vibration tests show a high degree of consistency for developing the perforated ultrasonic vibration platform with a maximum frequency error of 3%. The employment of ultrasonic vibration reduces the grinding force by 36% at most, thereby decreasing the machined surface defects, such as voids, cracks, and burnout.
Yang CAO , Biao ZHAO , Wenfeng DING , Qiang HUANG . Vibration characteristics and machining performance of a novel perforated ultrasonic vibration platform in the grinding of particulate-reinforced titanium matrix composites[J]. Frontiers of Mechanical Engineering, 2023 , 18(1) : 14 . DOI: 10.1007/s11465-022-0730-2
Abbreviations | |
AEM | Apparent elasticity method |
CG | Conventional grinding |
FEM | Finite element method |
L2T1 | Longitudinal full-wave and transverse halfwave |
PTMC | Particulate-reinforced titanium matrix composite |
UVAG | Ultrasonic vibration-assisted grinding |
Variables | |
ap | Depth of cut |
A | Ultrasonic amplitude |
Ax, Ay | Displacements along the x and y directions, respectively |
bw | Width of the workpiece |
E | Elasticity modulus |
E1x | Apparent elastic modulus along the x1-axis |
Eax, Eay | Apparent elastic modulus along the x and y directions, respectively |
f | Ultrasonic frequency |
f0 | Resonant frequency of the platform without holes |
fAEM-1, fFEM-1 | Resonant frequency of the platform only with top surface holes obtained through the modified AEM and FEM, respectively |
fAEM-2, fFEM-2 | Resonant frequency of the platform only with side surface holes obtained through the modified AEM and FEM, respectively |
F | Uniformly distributed force exerted on the side surface of the vibration unit |
Fn | Normal grinding force |
Ft | Tangential grinding force |
h | Thickness of the 1/4 vibration unit |
kf | Frequency reduction ratio |
kv | Volume reduction ratio |
kv1, kv2 | Reduction values of the platform volume when the top and side surface holes are generated, respectively |
kx, ky | Half-wave numbers along the x and y directions, respectively |
K1x, K1y | Influence of top surface holes on the apparent elastic modulus along the x and y directions, respectively |
K2x, K2y | Influence of side surface holes on the apparent elastic modulus along the x and y directions, respectively |
l1 | Distance to the edge of the vibration unit |
lm, ln | Length and width of the 1/4 vibration unit with a surface hole, respectively |
lp | Length of the vibration unit with a side surface hole |
lx, ly | Length and width of the vibration platform, respectively |
∆l1x | Elongation of the vibration unit along the force direction |
∆l1y, ∆l2y | Elongation of the vibration unit along the y1- and y2-axis, respectively |
m | Quantity of the top surface holes along the x direction |
n | Quantity of the top surface holes along the y direction |
nx, ny | Coupling coefficients along the x and y directions, respectively |
p | Quantity of side surface holes |
r1, r2 | Radii of the top and side surface holes, respectively |
Ra | Surface roughness |
S | Side area of the 1/4 vibration unit without holes |
vs | Grinding speed |
vw | Worktable infeed speed |
V | Volume of holes |
V0 | Volume of a vibration platform without holes |
ε(x1) | Strain along the x1 direction |
Average strain | |
η | Correction factor |
η1, η2 | Correction factors of top and side surface holes, respectively |
ν | Poisson’s ratio |
ρ | Material density |
σ | Stress |
σ(x1) | Stress along the x1 direction |
Average stress | |
χ | Correction factor of the vibration mode |
1 |
Chen Y R , Su H H , Qian N , He J Y , Gu J Q , Xu J H , Ding K . Ultrasonic vibration-assisted grinding of silicon carbide ceramics based on actual amplitude measurement: grinding force and surface quality. Ceramics International, 2021, 47(11): 15433–15441
|
2 |
Dai C W , Yin Z , Wang P , Miao Q , Chen J J . Analysis on ground surface in ultrasonic face grinding of silicon carbide (SiC) ceramic with minor vibration amplitude. Ceramics International, 2021, 47(15): 21959–21968
|
3 |
Wang Y D , Kang R K , Qin Y , Meng Q , Dong Z G . Effects of inclination angles of disc cutter on machining quality of Nomex honeycomb core in ultrasonic cutting. Frontiers of Mechanical Engineering, 2021, 16(2): 285–297
|
4 |
Lei X F , Xiang D H , Peng P C , Liu G F , Li B , Zhao B , Gao G F . Establishment of dynamic grinding force model for ultrasonic-assisted single abrasive high-speed grinding. Journal of Materials Processing Technology, 2022, 300: 117420
|
5 |
Xu S L , Kuriyagawa T , Shimada K , Mizutani M . Recent advances in ultrasonic-assisted machining for the fabrication of micro/nano-textured surfaces. Frontiers of Mechanical Engineering, 2017, 12(1): 33–45
|
6 |
Ma G F , Kang R K , Dong Z G , Yin S , Bao Y , Guo D M . Hole quality in longitudinal–torsional coupled ultrasonic vibration assisted drilling of carbon fiber reinforced plastics. Frontiers of Mechanical Engineering, 2020, 15(4): 538–546
|
7 |
Chen Y , Hu Z W , Yu Y Q , Lai Z Y , Zhu J G , Xu X P , Peng Q . Processing and machining mechanism of ultrasonic vibration-assisted grinding on sapphire. Materials Science in Semiconductor Processing, 2022, 142: 106470
|
8 |
Zhang M H , Pang Z X , Jia Y X , Shan C W . Understanding the machining characteristic of plain weave ceramic matrix composite in ultrasonic-assisted grinding. Ceramics International, 2022, 48(4): 5557–5573
|
9 |
Zhou W H , Tang J Y , Shao W , Wen J . Towards understanding the ploughing friction mechanism in ultrasonic assisted grinding with single grain. International Journal of Mechanical Sciences, 2022, 222: 107248
|
10 |
Naskar A , Choudhary A , Paul S . Surface generation in ultrasonic-assisted high-speed superabrasive grinding under minimum quantity cooling lubrication with various fluids. Tribology International, 2021, 156: 106815
|
11 |
Nik M G , Movahhedy M R , Akbari J . Ultrasonic-assisted grinding of Ti6Al4V alloy. Procedia CIRP, 2012, 1: 353–358
|
12 |
Bhaduri D , Soo S L , Novovic D , Aspinwall D K , Harden P , Waterhouse C , Bohr S , Mathieson A C , Lucas M . Ultrasonic assisted creep feed grinding of Inconel 718. Procedia CIRP, 2013, 6: 615–620
|
13 |
Bhaduri D , Soo S L , Aspinwall D K , Novovic D , Harden P , Bohr S , Martin D . A study on ultrasonic assisted creep feed grinding of nickel based superalloys. Procedia CIRP, 2012, 1: 359–364
|
14 |
Yang Z C , Zhu L D , Ni C B , Ning J S . Investigation of surface topography formation mechanism based on abrasive-workpiece contact rate model in tangential ultrasonic vibration-assisted CBN grinding of ZrO2 ceramics. International Journal of Mechanical Sciences, 2019, 155: 66–82
|
15 |
Yang Z C , Zhu L D , Lin B , Zhang G X , Ni C B , Sui T Y . The grinding force modeling and experimental study of ZrO2 ceramic materials in ultrasonic vibration assisted grinding. Ceramics International, 2019, 45(7): 8873–8889
|
16 |
Zhao B , Chang B Q , Wang X B , Bie W B . System design and experimental research on ultrasonic assisted elliptical vibration grinding of Nano-ZrO2 ceramics. Ceramics International, 2019, 45(18): 24865–24877
|
17 |
Kuo K L. Design of rotary ultrasonic milling tool using FEM simulation. Journal of Materials Processing Technology, 2008, 201(1–3): 48–52
|
18 |
Börner R , Winkler S , Junge T , Titsch C , Schubert A , Drossel W G . Generation of functional surfaces by using a simulation tool for surface prediction and micro structuring of cold-working steel with ultrasonic vibration assisted face milling. Journal of Materials Processing Technology, 2018, 255: 749–759
|
19 |
Azarhoushang B, Tawakoli T. Development of a novel ultrasonic unit for grinding of ceramic matrix composites. The International Journal of Advanced Manufacturing Technology, 2011, 57(9–12): 945
|
20 |
Azarhoushang B , Tawakoli T . Developing a special block sonotrode for ultrasonic-assisted grinding process. International Journal of Mechatronics and Manufacturing Systems, 2012, 5(2): 165–176
|
21 |
Han G C, Li K, Peng Z, Jin J S, Sun M, Wang X Y. A new porous block sonotrode for ultrasonic assisted micro plastic forming. The International Journal of Advanced Manufacturing Technology, 2017, 89(5–8): 2193–2202
|
22 |
Liu C J , Ding W F , Yu T Y , Yang C Y . Materials removal mechanism in high-speed grinding of particulate reinforced titanium matrix composites. Precision Engineering, 2018, 51: 68–77
|
23 |
Dong G J , Gao S D , Wang L . Three dimensional shape model of TiBw mesh reinforced titanium matrix composites in rotary ultrasonic grinding. Journal of Manufacturing Processes, 2022, 75: 682–692
|
24 |
Cao Y , Zhu Y J , Ding W F , Qiu Y T , Wang L F , Xu J H . Vibration coupling effects and machining behavior of ultrasonic vibration plate device for creep-feed grinding of Inconel 718 nickel-based superalloy. Chinese Journal of Aeronautics, 2022, 35(2): 332–345
|
25 |
Cao Y , Zhu Y J , Nan Li H , Wang C X , Su H H , Yin Z , Ding W F . Development and performance of a novel ultrasonic vibration plate sonotrode for grinding. Journal of Manufacturing Processes, 2020, 57: 174–186
|
26 |
Xu L , Qiu X J , Zhou J C , Li F M , Zhang H D , Wang Y B . A 2D dual-mode composite ultrasonic transducer excited by a single piezoceramic stack. Smart Materials and Structures, 2019, 28(2): 025017
|
27 |
Mani C , Balasubramani S , Karthikeyan R . Finite element simulation on effect of bevel angle and filler material on tensile strength of 316L stainless steel/Monel 400 dissimilar metal welded joints. Materials Today: Proceedings, 2020, 28(2): 1048–1053
|
28 |
Lin S Y . Design of piezoelectric sandwich ultrasonic transducers with large cross-section. Applied Acoustics, 1995, 44(3): 249–257
|
29 |
Mančić D D , Radmanović M D . Design of ultrasonic transducers by means of the apparent elasticity method. Facta Universitatis Series: Working and Living Environmental Protection, 2004, 2(4): 293–300
|
30 |
Li Z, Ding W F, Liu C J, Su H H. Grinding performance and surface integrity of particulate-reinforced titanium matrix composites in creep-feed grinding. The International Journal of Advanced Manufacturing Technology, 2018, 94(9–12): 3917–3928
|
31 |
Wang H , Pei Z J , Cong W L . A feeding-directional cutting force model for end surface grinding of CFRP composites using rotary ultrasonic machining with elliptical ultrasonic vibration. International Journal of Machine Tools and Manufacture, 2020, 152: 103540
|
32 |
Wu H , Yao Z Q . Force modeling for 2D freeform grinding with infinitesimal method. Journal of Manufacturing Processes, 2021, 70: 108–120
|
33 |
Yang Z Y, Zou P, Zhou L, Wang X. Research on modeling of grinding force in ultrasonic vibration-assisted grinding of 304 stainless steel materials. The International Journal of Advanced Manufacturing Technology, 2022, 120(5–6): 3201–3223
|
34 |
Li D G, Tang J Y, Chen H F, Shao W. Study on grinding force model in ultrasonic vibration-assisted grinding of alloy structural steel. The International Journal of Advanced Manufacturing Technology, 2019, 101(5–8): 1467–1479
|
35 |
Müller U , Prinz S , Barth S , Bergs T . Analysis of the thermo-mechanical load and productivity during force-compliant grinding of pcBN. Journal of Materials Processing Technology, 2022, 305: 117604
|
36 |
Liang Z Q , Wang X B , Wu Y B , Xie L J , Liu Z B , Zhao W X . An investigation on wear mechanism of resin-bonded diamond wheel in elliptical ultrasonic assisted grinding (EUAG) of monocrystal sapphire. Journal of Materials Processing Technology, 2012, 212(4): 868–876
|
37 |
Tao H F , Liu Y H , Zhao D W , Lu X C . Undeformed chip width non-uniformity modeling and surface roughness prediction in wafer self-rotational grinding process. Tribology International, 2022, 171: 107547
|
/
〈 |
|
〉 |