RESEARCH ARTICLE

Vibration characteristics and machining performance of a novel perforated ultrasonic vibration platform in the grinding of particulate-reinforced titanium matrix composites

  • Yang CAO ,
  • Biao ZHAO ,
  • Wenfeng DING ,
  • Qiang HUANG
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  • National Key Laboratory of Science and Technology on Helicopter Transmission, Nanjing University of Aeronautics and Astronautics, Nanjing 210016, China
zhaobiao@nuaa.edu.cn

Received date: 01 May 2022

Accepted date: 31 Jul 2022

Copyright

2023 Higher Education Press

Abstract

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.

Cite this article

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

Nomenclature

Abbreviations
AEMApparent elasticity method
CGConventional grinding
FEMFinite element method
L2T1Longitudinal full-wave and transverse halfwave
PTMCParticulate-reinforced titanium matrix composite
UVAGUltrasonic vibration-assisted grinding
Variables
apDepth of cut
AUltrasonic amplitude
Ax, AyDisplacements along the x and y directions, respectively
bwWidth of the workpiece
EElasticity modulus
E1xApparent elastic modulus along the x1-axis
Eax, EayApparent elastic modulus along the x and y directions, respectively
fUltrasonic frequency
f0Resonant frequency of the platform without holes
fAEM-1, fFEM-1Resonant frequency of the platform only with top surface holes obtained through the modified AEM and FEM, respectively
fAEM-2, fFEM-2Resonant frequency of the platform only with side surface holes obtained through the modified AEM and FEM, respectively
FUniformly distributed force exerted on the side surface of the vibration unit
FnNormal grinding force
FtTangential grinding force
hThickness of the 1/4 vibration unit
kfFrequency reduction ratio
kvVolume reduction ratio
kv1, kv2Reduction values of the platform volume when the top and side surface holes are generated, respectively
kx, kyHalf-wave numbers along the x and y directions, respectively
K1x, K1yInfluence of top surface holes on the apparent elastic modulus along the x and y directions, respectively
K2x, K2yInfluence of side surface holes on the apparent elastic modulus along the x and y directions, respectively
l1Distance to the edge of the vibration unit
lm, lnLength and width of the 1/4 vibration unit with a surface hole, respectively
lpLength of the vibration unit with a side surface hole
lx, lyLength and width of the vibration platform, respectively
∆l1xElongation of the vibration unit along the force direction
∆l1y, ∆l2yElongation of the vibration unit along the y1- and y2-axis, respectively
mQuantity of the top surface holes along the x direction
nQuantity of the top surface holes along the y direction
nx, nyCoupling coefficients along the x and y directions, respectively
pQuantity of side surface holes
r1, r2Radii of the top and side surface holes, respectively
RaSurface roughness
SSide area of the 1/4 vibration unit without holes
vsGrinding speed
vwWorktable infeed speed
VVolume of holes
V0Volume of a vibration platform without holes
ε(x1)Strain along the x1 direction
ε¯Average strain
ηCorrection factor
η1, η2Correction factors of top and side surface holes, respectively
νPoisson’s ratio
ρMaterial density
σStress
σ(x1)Stress along the x1 direction
σ¯Average stress
χCorrection factor of the vibration mode

Acknowledgements

This work was financially supported by the National Natural Science Foundation of China (Grant Nos. 51921003, 92160301, 52175415 and 52205475), the Science Center for Gas Turbine Project, China (Grant No. P2022-A-IV-002-001), the Natural Science Foundation of Jiangsu Province, China (Grant No. BK20210295), and the Postgraduate Research & Practice Innovation Program of Jiangsu Province, China (Grant No. KYCX20_0179).
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