Vibration assisted machining is becoming a potential machining process for difficult-to-cut materials in aerospace and biomedical applications. This book presents the fundamentals, modelling and applications of vibration assisted machining process. It provides investigations on cutting forces, temperature, cutting stability, surface topography, microstructure evolution and tool wear in vibration assisted machining. Three representative regimes (i.e., ultrasonically assisted machining, modulation assisted machining and elliptical vibration machining) are investigated in this book. The systematic and in-depth research in this process will provide important theoretical and practical reference for researchers and engineers in relative fields.
Author(s): Wei Bai, Yuan Gao, Ronglei Sun
Series: Research on Intelligent Manufacturing
Publisher: Springer
Year: 2023
Language: English
Pages: 219
City: Singapore
Preface
Contents
Contributors
1 Introduction
1.1 Outline of Vibration Assisted Machining
1.2 The State of Art and Trend
References
2 Fundamentals and System of Vibration Assisted Machining
2.1 Types of Vibration Assisted Machining
2.1.1 Frequency-Based Classification
2.1.2 Direction-Based Classification
2.1.3 Dimension-Based Classification
2.2 Benefits of Vibration Assisted Machining
2.2.1 Cutting Forces
2.2.2 Surface Quality
2.2.3 Tool Wear
2.2.4 Cutting Stability
2.3 System and Components of Vibration Assisted Machining
2.3.1 Vibration Device
2.3.2 Vibration Generator
2.3.3 Vibration Transducer
2.4 Summary
References
3 Kinematics of Vibration Assisted Cutting
3.1 Introduction
3.2 Kinematics of Ultrasonically Assisted Cutting
3.2.1 Kinematics Characteristic
3.2.2 Relative Cutting Velocity
3.3 Kinematics of Modulation Assisted Cutting
3.3.1 Kinematics Characteristic
3.3.2 Realization of Discrete Chip Formation
3.3.3 Cutting Thickness and Cutting Angles
3.4 Kinematics of Elliptical Vibration Cutting
3.5 Summary
References
4 Cutting Forces in Vibration Assisted Cutting
4.1 Introduction
4.2 Cutting Forces in Ultrasonically Assisted Cutting
4.2.1 Shear Angle
4.2.2 Tool-Chip Frictional Behaviour
4.2.3 Analytical Modelling and Parameter Prediction
4.3 Cutting Forces in Modulation Assisted Cutting
4.3.1 Force Modelling of Modulation Assisted Face Turning
4.3.2 Force Modelling for Reverse Cutting Phase
4.3.3 Identification and Validation of the Model Parameters
4.3.4 Validation of the Analytical Force Model
4.4 Cutting Forces in Elliptical Vibration Cutting
4.4.1 Analysis of the Force Model
4.4.2 Experiments and Discussions
4.5 Summary
References
5 Temperature in Vibration Assisted Cutting
5.1 Introduction
5.2 Analytical Modelling of Tool Temperature
5.2.1 Geometric Simplification and Temperature Modeling of Tool
5.2.2 Calculation of Tool Temperature
5.3 Numerical Modelling of Tool Temperature
5.3.1 Simulation of Tool Heat Conduction with Abaqus
5.3.2 Simulation of Orthogonal Cutting with AdvantEdge
5.4 Experimental Investigations of Tool Temperature
5.5 Summary
References
6 Cutting Stability in Vibration Assisted Cutting
6.1 Introduction
6.2 Cutting Stability in Orthogonal Cutting
6.2.1 Free Vibrations in the Machine-Tool System
6.2.2 Regenerative Chatter Phenomenon
6.3 Cutting Stability in Vibration Assisted Cutting
6.3.1 Analytical Modeling of Cutting Stability
6.3.2 Stability Analysis for Vibration Assisted Cutting
6.3.3 Case Study and Verification by Time-Domain Simulation
6.4 Summary
References
7 Surface Topography and Roughness in Vibration Assisted Machining
7.1 Introduction
7.2 Analysis of Surface Topography and Roughness
7.2.1 Surface Topography and Roughness Modeling
7.2.2 Analysis of the Effect of Modulation Conditions
7.3 Experimental Investigations of Surface Topography and Roughness
7.3.1 Qualitative Experimental Verification
7.3.2 Quantitative Experimental Verification
7.4 Summary
References
8 Microstructural Evolution in Vibration Assisted Cutting
8.1 Introduction
8.2 Numerical Models of Microstructural Evolution
8.3 Microstructural Evolution of Machined Surface
8.3.1 Status Tracking of Machined Surface
8.3.2 Numerical Results for Microstructural Evolution
8.3.3 Experimental Results for Machined Surface
8.4 Microstructural Evolution of Chip
8.4.1 Status Tracking of Chip
8.4.2 Numerical Results for Microstructural Evolution
8.4.3 Experimental Results for Chip
8.5 Summary
References
9 Tool Wear in Vibration Assisted Machining
9.1 Introduction
9.2 Tool Wear in Ultrasonically Assisted Machining
9.2.1 Machining Experiment Material and Setup
9.2.2 Assessment of Tool Wear
9.3 Tool Wear in Modulation Assisted Machining
9.3.1 Microscopic Observation of Tool Wear
9.3.2 Analysis the Influencing Factors of Tool Wear Rate
9.3.3 Effect of Temperature on Tool Wear Rate
9.4 Summary
References
10 Aerospace Applications of Vibration Assisted Machining
10.1 Introduction
10.2 Machining of Aerospace-Grade Inconel Alloys
10.2.1 Experiment Setup
10.2.2 Workpiece Material
10.2.3 Machine Tool and Machining Conditions
10.2.4 Results and Discussions
10.3 Machining of Metal Matrix Composite
10.3.1 Experiment Setup and Machining Conditions
10.3.2 Results and Discussions
10.4 Summary
References
11 Biomedical Applications of Vibration Assisted Machining
11.1 Introduction
11.2 Machining of Bone Tissue
11.2.1 Characteristics of Cortical Bone and Sample Preparation
11.2.2 Impact Cutting Method and Experiment Setup
11.2.3 Experiment Results and Discussions
11.3 Machining of Soft Tissue
11.4 Summary
References
