Design of five-axis ultrasonic assistant compound machine tool

Abstract

A compound machine tool was designed, which combined rotary ultrasonic assisted grinding, electrical discharge machining (EDM) and multi-axis milling. Experimental results indicated that its positioning accuracy was less than 5.6 µm and its repetitive positioning accuracy was less than 1.8 µm; the vibration amplitude of ultrasonic grinding system was uniform and stable, and the EDM system worked well and stably. A smooth surface of K9 optical glass component was achieved by the grinding method.

Keywords

ultrasonic assisted grinding / electrical discharge machining / machine tool / design

References

[1] Barta J, Manela M. Si₃N₄ and Si₂N₂O for high performance radome[J]. Materials Science and Engineering, 1985, 71: 265-272.

[2] Honjo K, Hashimoto R, Ogiyama H. Current status of 300 kW industrial ceramic gas turbine R&D in Japan[J]. ASME Journal of Engineering for Gas Turbines and Power, 1993, 115(1): 51-57.

[3] Kuo K L, Tsao C C. Rotary ultrasonic-assisted milling of brittle materials[J]. Transactions of Nonferrous Metals Society of China, 2012, 22(3): 793-800.

[4] Moriwaki T. Multi-functional machine tool[J]. CIRP Annals-Manufacturing Technology, 2008, 57(2): 736-749.

[5] Aspinwall D K, Dewes R C, Burrows J M, et al. Hybrid high speed machining(HSM): System design and experimental results for grinding/HSM and EDM/HSM[J]. CIRP Annals-Manufacturing Technology, 2001, 50(1): 145-148.

[6] Rahman M, Asad A B M A, Masaki T, et al. A multiprocess machine tool for compound micromachining[J]. International Journal of Machine Tools and Manufacture, 2010, 50(4): 344-356.

[7] Kang I S, Kim J S, Seo Y W, et al. An experimental study on the ultrasonic machining characteristics of engineering ceramics[J]. Journal of Mechanical Science and Technology, 2006, 20(2): 227-233.

[8] Liu J W, Baek D K, Ko T J. Chipping minimization in drilling ceramic materials with rotary ultrasonic machining[J]. The International Journal of Advanced Manufacturing Technology, 2014, 72(9-12): 1527-1535.

[9] Thoe T B, Aspinwall D K, Wise M L H. Review on ultrasonic machining[J]. International Journal of Machine Tools and Manufacture, 1998, 38(4): 239-255.

[10] Nakagawa T, Suzuki K, Uematsu T, et al. Development of a new turning center for grinding ceramic materials[J]. CIRP Annals-Manufacturing Technology, 1988, 37(1): 319-322.

[11] Wiercigroch M, Wojewoda J, Krivtsov A M. Dynamics of ultrasonic percussive drilling of hard rocks[J]. Journal of Sound and Vibration, 2005, 280: 739-757.

[12] Li H T, Lai X M, Li C F, et al. Development of meso-scale milling machine tool and its performance analysis[J]. Frontiers of Mechanical Engineering in China, 2008, 3(1): 59-65.

[13] Lee S W, Mayor R, Ni J. Dynamic analysis of a mesoscale machine tool[J]. Journal of Manufacturing Science and Engineering, 2006, 128(1): 194-203.

[14] Bang Y B, Lee K M, Oh S. 5-axis micro milling machine for machining micro parts[J]. The International Journal of Advanced Manufacturing Technology, 2005, 25: 888-894.

[15] Mahapatra S S, Patnaik A. Optimization of wire electrical discharge machining(WEDM)process parameters using Taguchi method[J]. The International Journal of Advanced Manufacturing Technology, 2007, 34: 911-925.

[16] Maher I, Sarhan A A D, Hamdi M. Review of improvements in wire electrode properties for longer working time and utilization in wire EDM machining[J]. The International Journal of Advanced Manufacturing Technology, 2015, 76(1-4): 329-351.