The Experts below are selected from a list of 1185 Experts worldwide ranked by ideXlab platform
Eiji Shamoto - One of the best experts on this subject based on the ideXlab platform.
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Study on Process Monitoring of Elliptical Vibration Cutting by Utilizing Internal Data in Ultrasonic Elliptical Vibration Device
International Journal of Precision Engineering and Manufacturing-Green Technology, 2018Co-Authors: Hongjin Jung, Takehiro Hayasaka, Eiji ShamotoAbstract:In the present study, monitoring of Elliptical Vibration cutting process by utilizing internal data in the ultrasonic Elliptical Vibration device without external sensors such as a dynamometer and displacement sensor is investigated. The internal data utilized here is the change of excitation frequency, i.e. resonant frequency of the device, voltages applied to the piezoelectric actuators composing the device, and electric currents flowing through the actuators. These internal data change automatically in the Elliptical Vibration control system in order to keep a constant Elliptical Vibration against the change of the cutting process. Correlativity between the process and the internal data is described by using a Vibration model of ultrasonic Elliptical Vibration cutting and verified by several experiments, i.e. planing and mirror surface finishing of hardened die steel carried out with single crystalline diamond tools. As a result, it is proved that it is possible to estimate the elements of Elliptical Vibration cutting process, e.g. tool wear and machining load, which are important for stable cutting in such precision machining.
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Mirror Surface Machining of Steel by Elliptical Vibration Cutting with Diamond-Coated Tools Sharpened by Pulse Laser Grinding
International Journal of Automation Technology, 2018Co-Authors: Hiroshi Saito, Hongjin Jung, Eiji Shamoto, Shinya Suganuma, Fumihiro ItoigawaAbstract:Low-cost mirror surface machining of die steel is proposed in this research by applying Elliptical Vibration cutting with diamond-coated tools sharpened by pulse laser grinding (PLG). It is well known that conventional diamond cutting cannot be applied to die steel owing to rapid tool wear. Several attempts have been reported to prevent rapid tool wear, such as using ultrasonic Elliptical Vibration cutting. The ultrasonic Elliptical Vibration cutting developed by the authors to achieve mirror surface finish on die steel and prevent rapid wear is widely used in the industry. However, high-cost single-crystalline diamond tools that are finished using a time-consuming lapping process are required to obtain mirror surfaces. The authors, meanwhile, have recently developed the PLG process to efficiently sharpen the cutting edges of hard tool materials such as cubic boron nitride. Therefore, a practical mirror surface machining method for die steel is proposed in this research, namely Elliptical Vibration cutting with low-cost diamond-coated tools sharpened by the efficient PLG process. The results of the machining experiments confirmed that practical mirror surface machining of die steel can be achieved by the proposed method.
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Elliptical Vibration cutting of hardened die steel with coated carbide tools
Precision Engineering, 2016Co-Authors: Hiroshi Saito, Hongjin Jung, Eiji ShamotoAbstract:Abstract Elliptical Vibration cutting of hardened die steel with coated carbide tools is examined in this research in order to achieve low-cost high-precision machining. Diamond coated tools are applied because of superior hardness of their polycrystalline diamond coating and its low manufacturing cost. TiN coated tools are also tested, since they are widely used for conventional machining of steels. Machinability of hardened die steel by the Elliptical Vibration cutting with coated carbide tools is discussed in three aspects in this study, i.e. transferability of cutting edge profile to cut surface, cutting force, and tool life. The transferability is evaluated quantitatively by calculating correlation coefficients of measured roughness profiles. It is clarified that the diamond coated tools have high transferability which leads to diffraction of light on the surface machined at micro-scale pick feed. Total cutting forces including ploughing components are measured at various feed rates, and then shearing components and ploughing components are separated utilizing linear regression. The measured results indicate, for example, that the all forces become considerably smaller only when Elliptical Vibration is applied to the TiN coated tool without cutting fluid. It is also found that this considerable reduction of forces interestingly corresponds to higher friction coefficient, which is identified from the ploughing components. Tool life tests are carried out by various machining methods, i.e. Elliptical Vibration/ordinary wet/dry cutting with diamond/TiN coated tools. The result shows, for example, that the flank wear is smallest in the wet Elliptical Vibration cutting with the diamond coated tool.
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Mechanism and suppression of frictional chatter in high-efficiency Elliptical Vibration cutting
CIRP Annals - Manufacturing Technology, 2016Co-Authors: Hongjin Jung, Takehiro Hayasaka, Eiji ShamotoAbstract:This research clarifies the mechanism of undesirable Vibration observed during high-efficiency Elliptical Vibration cutting. Elliptical Vibration cutting has recently been utilized in practice, and some applications require high-efficiency machining at large width of cut causing Vibration problems. Therefore, its mechanism is investigated by analyzing the finished surfaces and the undesirable Vibrations superimposed on the Elliptical Vibration. The Vibration is clarified as a kind of frictional chatter induced by ploughing on the tool flank at the beginning of cutting in Elliptical Vibration cycles and has unique characteristics such as occurrence with sharp tools, low amplitude, and surface waviness at beat frequency.
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Elliptical Vibration Cutting of Hardened Steel with Large Nose Radius Single Crystal Diamond Tool
International Journal of Automation Technology, 2014Co-Authors: Yilong Wang, Eiji ShamotoAbstract:It has been verified that ultra-precision diamond machining of hardened steel can be realized by applying the Elliptical Vibration cutting process. This innovative machining technology enables direct machining of steel dies and molds with a single crystal diamond tool and makes the indispensable nickel-plating step in the conventional diamond machining process unnecessary. This not only increases mold tool life, but also reduces the machining cost and cycle time. Therefore, Elliptical Vibration cutting has been considered as a very promising manufacturing technology for high precision die and mold machining. However, progress in Elliptical Vibration cutting has been hampered by bottlenecks in machining of large-size steel workpieces owing to the low machining efficiency. This study proposed an efficient machining method, Elliptical Vibration cutting with a large nose radius single crystal diamond tool. Experimental findings revealed that the proposed machining method had great potential to realize efficient ultra-precision diamond machining of hardened steel. However, it was found that the ploughing phenomenon affected the finished surface quality significantly. To minimize the ploughing effect an analytical model was developed. This model enabled minimization of the ploughing effect by optimizing the machining conditions. Finally, the analytical model was qualitatively validated with a series of plane cutting experiments and the experimental results demonstrated good agreement with the analytical model.
N. Suzuki - One of the best experts on this subject based on the ideXlab platform.
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11 16 ultrasonic Vibration diamond cutting and ultrasonic Elliptical Vibration cutting
Reference Module in Materials Science and Materials Engineering#R##N#Comprehensive Materials Processing, 2014Co-Authors: Eiji Shamoto, N. SuzukiAbstract:The ultraprecision/micro diamond cutting is widely utilized to produce many electronic and optical parts, but it cannot be applied to machining of steel because of excessive tool wear. In order to solve this problem, ultrasonic Vibration diamond cutting has been applied successfully to mirror surface finishing of steel. Based on this Vibration cutting, two-directional Vibration cutting, named Elliptical Vibration cutting, was developed recently, which considerably improves cutting performance in terms of tool life, surface quality, and applicability to free-form surface machining and micromachining. These conventional Vibration cutting and Elliptical Vibration cutting technologies are reviewed as well as their devices and applications not only to steel but also to other difficult-to-cut materials in this chapter.
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11.16 – Ultrasonic Vibration Diamond Cutting and Ultrasonic Elliptical Vibration Cutting
Comprehensive Materials Processing, 2014Co-Authors: Eiji Shamoto, N. SuzukiAbstract:The ultraprecision/micro diamond cutting is widely utilized to produce many electronic and optical parts, but it cannot be applied to machining of steel because of excessive tool wear. In order to solve this problem, ultrasonic Vibration diamond cutting has been applied successfully to mirror surface finishing of steel. Based on this Vibration cutting, two-directional Vibration cutting, named Elliptical Vibration cutting, was developed recently, which considerably improves cutting performance in terms of tool life, surface quality, and applicability to free-form surface machining and micromachining. These conventional Vibration cutting and Elliptical Vibration cutting technologies are reviewed as well as their devices and applications not only to steel but also to other difficult-to-cut materials in this chapter.
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Analysis of 3D Elliptical Vibration cutting with thin shear plane model
CIRP Annals - Manufacturing Technology, 2008Co-Authors: Eiji Shamoto, N. Suzuki, Rei HinoAbstract:Simple analytical models of three dimensional (3D) Elliptical Vibration cutting are developed in order to simulate the cutting process quickly and to understand the basic mechanics. The Elliptical Vibration cutting has recently been applied in industry mainly to ultraprecision machining of dies and molds, where the Vibration locus is not generally perpendicular to the cutting edge and thus all directions of shear, chip flow and cutting force have the 3D components. Therefore, the 3D Elliptical Vibration cutting models are developed, and the basic cutting mechanics are discussed in the present research. © 2008.
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Elliptical Vibration cutting of tungsten alloy molds for optical glass parts
CIRP Annals - Manufacturing Technology, 2007Co-Authors: N. Suzuki, Rei Hino, Makoto Haritani, Jihui Yang, Eiji ShamotoAbstract:Elliptical Vibration cutting is applied to ultra-precision machining of tungsten alloy molds for optical glass parts in the present research. The tungsten alloy is expected as a new mold material instead of conventional ones such as sintered tungsten carbide and CVD-silicon carbide. However, it cannot be finished precisely by ordinary cutting because of rapid tool wear, brittle fracture and adhesion to the tool. Therefore, the ultrasonic Elliptical Vibration cutting is applied to the ultra-precision machining of tungsten alloy. Practical ultra-precision molds are obtained by the Elliptical Vibration cutting, and they are applied to glass molding successfully.
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Development of 3 DOF ultrasonic Vibration tool for Elliptical Vibration cutting of sculptured surfaces
CIRP Annals - Manufacturing Technology, 2005Co-Authors: Eiji Shamoto, Eiji Tsuchiya, Hiroshi Inagaki, Y Hori, N. Suzuki, K. YoshinoAbstract:A new machining method is proposed to obtain sculptured mirror surfaces by applying Elliptical Vibration cutting. The tool is vibrated Elliptically unlike rotated end mills and fed along the sculptured surface in the proposed method. A 3 DOF ultrasonic Vibration tool is developed, which can generate an arbitrary ultrasonic Elliptical Vibration in the 3D space so that it is suitable to machine the 3D sculptured surfaces. A precision machine tool is also developed, and the proposed method is successfully applied to mirror surface machining of hardened die steel.
Toshimichi Moriwaki - One of the best experts on this subject based on the ideXlab platform.
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analysis of regenerative chatter suppression with adding the ultrasonic Elliptical Vibration on the cutting tool
Precision Engineering-journal of The International Societies for Precision Engineering and Nanotechnology, 2011Co-Authors: Eiji Shamoto, Toshimichi MoriwakiAbstract:A method is proposed to suppress regenerative chatter in turning operation, in which the ultrasonic Elliptical Vibration is added on the cutting tool. It results in the fact that the cutting tool is separated periodically from the chip and the workpiece, and the direction of the frictional force between the rake face of the cutting tool and the chip is reversed in each cycle of the ultrasonic Elliptical Vibration. The experimental investigations show that the regenerative chatter occurring in ordinary turning operation can be suppressed effectively by applying the ultrasonic Elliptical Vibration on the cutting tool. In order to clearify the reason of the regenerative chatter suppression, theoretical analysis and computer simulation are performed on turning with ultrasonic Vibration. There is a good agreement among the experimental investigations, theoretical analysis and the computer simulation.
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Mirror finishing of Co―Cr―Mo alloy using Elliptical Vibration cutting
Precision Engineering, 2010Co-Authors: Young Chan Song, Chun-hong Park, Toshimichi MoriwakiAbstract:Abstract The biocompatibility and fatigue strength of Co–Cr–Mo alloy are excellent, making it suitable for the use in artificial joints. The head of an artificial joint must have a mirrored surface to reduce abrasive resistance. Mirror finishing of Co–Cr–Mo alloy with single-crystal diamond cutting tools is hindered by microchipping of the tool edge. It is generally believed that microchipping of diamond tools is caused by work hardening of the Co–Cr–Mo alloy during the cutting process. In the present research, mirror finishing of Co–Cr–Mo alloy was carried out using Elliptical Vibration cutting, as well as by ordinary cutting. The experimental results show that Elliptical Vibration cutting offers superior performance compared to ordinary diamond cutting without tool Vibration. Microchipping, tool wear, and work hardening were all significantly reduced. A fine mirrored surface (with maximum surface roughness under 25 nmP-V) was maintained up to a cutting length of about 14 m. As a practical consequence, Elliptical Vibration cutting was successfully applied to the mirror finishing of a femoral head.
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Development of 2DOF Ultrasonic Vibration Cutting Device for Ultraprecision Elliptical Vibration Cutting
Key Engineering Materials, 2010Co-Authors: Toshimichi MoriwakiAbstract:A new ultrasonic Vibration cutting device for ultraprecision Elliptical Vibration cutting has been developed. The Elliptical Vibration cutting device developed utilizes combination of bending and longitudinal modes of Vibration of the stepped vibrator to generate circular or Elliptical Vibration locus at the cutting tool edge. The design principle as well as the structure and the performance of the Elliptical Vibration cutting device is introduced here. The experimental results of diamond cutting of Co-Cr-Mo Alloy proved that good surface quality with roughness of 20 nmPV can be obtained stably with the Elliptical Vibration cutting device developed.
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suppression of burrs in turning with ultrasonic Elliptical Vibration cutting
International Journal of Machine Tools & Manufacture, 2005Co-Authors: Eiji Shamoto, Toshimichi Moriwaki, Yonghong Zhang, Lijiang WangAbstract:The approximate cutting force models in three-dimensional separating type ultrasonic Elliptical Vibration cutting are proposed in present paper. The theoretical models of the stresses of deformation zone on the workpiece edge in burr formation in ultrasonic Elliptical Vibration cutting are derived based on three-dimensional cutting model, and the reason for the burr being suppressed by applying ultrasonic Elliptical Vibration is clarified theoretically. Finally, the effect of ultrasonic Elliptical Vibration cutting on the burr is verified experimentally.
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Drilling Assisted by Ultrasonic Elliptical Vibration
Key Engineering Materials, 2005Co-Authors: Eiji Shamoto, Toshimichi MoriwakiAbstract:The drilling assisted by ultrasonic Elliptical Vibration (UEV) is proposed in present paper. The drilling system assisted by UEV was developed. The characteristics of the drilling process assisted by UEV are analyzed. The effect of ultrasonic Elliptical Vibration on the axial drilling force, the radial drilling force and the chip thickness are investigated experimentally. The experimental results show that the axial drilling force, the variation of the radial drilling force and the chip thickness of drilling assisted by UEV can be reduced.
Kornel F. Ehmann - One of the best experts on this subject based on the ideXlab platform.
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ultrasonic Elliptical Vibration cutting of hard materials simulation and experimental study
The International Journal of Advanced Manufacturing Technology, 2017Co-Authors: Ping Zou, Wule Zhu, Kornel F. EhmannAbstract:In this paper, orthogonal cutting experiments and a simulation analysis of ultrasonic Elliptical Vibration cutting (UEVC) of hard material were performed by adopting a resonant UEVC actuator. The effects of the cutting regime parameters (ultrasonic Elliptical Vibration excitation, cutting speed, crossfeed, and depth of cut) on the cutting resistance, chip morphology, and surface integrity during the UEVC process were experimentally investigated. The von Mises stress distribution in the primary deformation zone in one ultrasonic Elliptical Vibration cycle was used to describe the cutting nature of UEVC. It was also shown through both analysis and experiments that the cutting resistance in UEVC is lower as compared to conventional cutting. At last, the different nature of the chip formation mechanisms in the two processes were also analyzed through a free body force analysis of the chip. The chip shapes from experiments and finite element analysis (FEA) are compared and discussed based on the average equivalent plastic strain in the chip.
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Modeling of the effects of phase shift on cutting performance in Elliptical Vibration cutting
The International Journal of Advanced Manufacturing Technology, 2017Co-Authors: Wule Zhu, Kornel F. Ehmann, Zhiwei ZhuAbstract:In the Elliptical Vibration cutting process, the Elliptical locus is considered to be a vital factor that affects cutting performance. Besides the cutting speed and Vibration amplitudes, the phase shift (i.e., the phase difference between the two-directional output harmonic Vibrations forming the Elliptical locus) is an intrinsic parameter that determines the shape and inclination of the Elliptical locus with respect to the cutting direction. In this paper, a numerical recursive search method is proposed to investigate the effect of phase shift in Elliptical Vibration cutting. It has been shown that the critical speed ratio for considerably improving the cutting performance has a sinusoidal correlation with the phase shift. For Elliptical loci with arbitrary shapes, the developed model theoretically predicts the maximal influential thickness of cut, surface roughness, and the tool-workpiece contact ratio as a function of phase shifts. Experiments were conducted to validate the developed model through the evaluation of the machined surface profile, roughness, and dynamic cutting force. The obtained results offer a method to determine the proper machining variables in cutting hard and brittle materials during the Elliptical Vibration cutting process with an arbitrary locus.
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Investigation of hybrid micro-texture fabrication in Elliptical Vibration-assisted cutting
International Journal of Machine Tools and Manufacture, 2017Co-Authors: Chen Zhang, Guilin Shi, Kornel F. EhmannAbstract:Abstract Various micro-texturing methods have been used to control surface topography. However, most of the available methods are inherently difficult to adopt for the efficient generation of intricate micro-textures on cylindrical surfaces. In this paper, a novel ultrasonic Elliptical Vibration-assisted cutting technique based on a micro-texturing model is proposed to fabricate hybrid micro-textures with different geometric characteristics. In the proposed Elliptical Vibration-assisted hybrid micro-texturing method an intricately shaped primary micro-texture is generated by Elliptical Vibration-assisted cutting, while the desired secondary textures are simultaneously constructed through a controlled intersection with neighboring Elliptical Vibration-assisted cutting loci. The cutting loci for the fabrication of the hybrid micro-textures is mathematically calculated according to a geometric model of hybrid micro-texturing. The topography of the hybrid dimples is analyzed to verify the correctness of the cutting locus generation method. Locus compensation methods, considering the Elliptical Vibration locus and the tool nose radius are proposed to reduce fabrication errors during the hybrid dimple generation process. Micro-scale hybrid dimples, which are in close compliance with the results of the mathematical calculations, were successfully fabricated on machined cylindrical surfaces. The comparison of the results shows that the proposed method is satisfactory and can be used to predict and generate hybrid micro-textures on cylindrical surfaces.
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Modeling and simulation of micro-groove topography on cylindrical surface by Elliptical Vibration-assisted turning
The International Journal of Advanced Manufacturing Technology, 2016Co-Authors: Chen Zhang, Guilin Shi, Kornel F. EhmannAbstract:Micro-grooving, as a form of surface texturing, has a wide array of industrial applications. However, the majority of micro-grooving operations have been mainly done for flat surfaces. In this paper, ultrasonic Elliptical Vibration is used to assist micro-groove turning on cylindrical surfaces and model of micro-groove topography on cylindrical surface by Elliptical Vibration-assisted turning is investigated. First, Elliptical Vibration-assisted micro-groove generation process on cylindrical surface is analyzed by considering the geometry of tool and the cross-sectional area of chip in each Vibration cycle. Then, the model of micro-groove topography on cylindrical surface is established by combining the tool tip arc curve and the ultrasonic Elliptical Vibration-assisted cutting locus curve. In the modeling process, the trajectory equation of tool tip arc curve in Elliptical Vibration process is obtained by sweeping tool tip arc curve along Elliptical Vibration locus. Surface topography equation of micro-groove considering the machining parameters and Vibration parameters can be obtained based on the established trajectory equation of tool tip arc. Thus, model of micro-groove topography on cylindrical surface is constructed based on the Boolean operation between the cylindrical surface and the obtained surface topography equation of micro-groove. Finally, simulation algorithm of micro-groove generation process is proposed based on surface topography model of micro-groove on cylindrical surface in details. The influence of machining parameters and Vibration parameters on micro-groove generation is analyzed and compared based on the established surface topography model and the proposed simulation algorithm. In order to validate the proposed surface topography model and simulation algorithm, a series of micro-groove cutting experiments under different machining conditions are performed to verify the predicted effect of the established simulation model. The results show that the simulation of the established micro-groove generation model correlates well with the experimental results.
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Turning of Microgrooves Both With and Without Aid of Ultrasonic Elliptical Vibration
Materials and Manufacturing Processes, 2015Co-Authors: Chen Zhang, Ping Guo, Kornel F. EhmannAbstract:Microgroove, as a form of surface texturing, has a wide array of industrial applications. However, the use of conventional methods to machine microgrooves leads to a number of problems including large burrs, high cutting forces, and poor machining quality. In this paper, ultrasonic Elliptical Vibration cutting is used to assist microgrooves turning on cylindrical workpiece surfaces. The Elliptical locus in the cutting process is generated by a newly designed 2D resonant ultrasonic vibrator. A series of microgrooves cutting experiments without and with the ultrasonic Elliptical Vibration-assistance is performed to verify the effects of the ultrasonic Elliptical Vibrations as compared to the ordinary cutting method. The generated cutting forces, burr suppression action, and microgroove surface quality are compared for the two classes of processes. Comparison results show the effectiveness of Elliptical Vibration-assisted microgroove cutting in reducing cutting forces and improving microgrooves machining qua...
Ping Guo - One of the best experts on this subject based on the ideXlab platform.
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modulated ultrasonic Elliptical Vibration cutting for ductile regime texturing of brittle materials with 2 d combined resonant and non resonant Vibrations
International Journal of Mechanical Sciences, 2020Co-Authors: Jianjian Wang, Wei-hsin Liao, Ping GuoAbstract:Abstract In this study, modulated ultrasonic Elliptical Vibration cutting (modulated UEVC) is proposed to generate micro-structured surfaces on brittle materials in ductile-regime. A novel tool is first developed to generate 2-D combined resonant and non-resonant Vibrations in a single compact structure. The ultrasonic Elliptical Vibration is excited at the coupled resonant frequency of 20 kHz to enhance the ductile-to-brittle transition depth, while the simultaneously generated non-resonant modulation motion (up to 2 kHz) is used to adjust the tool center to generate surface structures dynamically. A theoretical model is established to analyze the instantaneous uncut chip thickness in modulated UEVC by considering a more general case of an inclined Elliptical Vibration trajectory. The analysis indicates that the orientation angle of 135° is optimal to achieve the maximal critical depth-of-cut in ductile-regime cutting. Experimental results are provided to demonstrate the process capability and to verify the proposed theoretical model. Micro dimple arrays have been successfully generated using the proposed modulated UEVC for a depth-of-cut up to 700 nm in ductile-regime, and an extended depth-of-cut up to 1 µm with minimal surface damage.
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On ductile-regime Elliptical Vibration cutting of silicon with identifying the lower bound of practicable nominal cutting velocity
Journal of Materials Processing Technology, 2020Co-Authors: Jianjian Wang, Yang Yang, Zhiwei Zhu, Yaoke Wang, Wei-hsin Liao, Ping GuoAbstract:Abstract This study investigates the ductile-to-brittle transition behavior in Elliptical Vibration cutting (EVC) of silicon and identifies the practical process window for ductile-regime cutting. EVC has been reported to increase the critical depth of ductile-regime cutting of silicon. This study demonstrates that the enhanced ductile cutting performance, however, is only optimal in a carefully-determined process window. The Vibration amplitudes and nominal cutting velocity have significant impacts on the ductile-to-brittle transition behaviors. Systematic experiments covering a wide span of Vibration amplitudes and cutting velocity have been conducted to investigate their effects. Two quantitative performance indices, the critical depth and ductile ratio, are utilized to analyze cutting performance by considering two unique characteristics of Elliptical Vibration cutting, i.e., the time-varying undeformed chip thickness and effective cutting direction angle. The results show that there exists a lower bound for the nominal cutting velocity to ensure the ductile-regime material removal, besides the well-known upper bound. Besides, the increases of Vibration amplitudes in both the cutting and depth-of-cut (DOC) directions first enhance but then deteriorate the cutting performance. Based on the theoretical analysis and experimental results, the optimal process parameters have been recommended for the Elliptical Vibration cutting of silicon.
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Fabrication of structurally colored basso-relievo with modulated Elliptical Vibration texturing
Precision Engineering, 2020Co-Authors: Jianjian Wang, Yang Yang, Yaoke Wang, Wei-hsin Liao, Ru Yang, Ping GuoAbstract:Abstract Elliptical Vibration texturing is a newly arising method for the fast and cost-effective generation of near-subwavelength micro-structures on metal surfaces. This study proposes a fabrication method for structurally colored basso-relievo by combining the surface sculpturing and Elliptical Vibration texturing in one-step machining. Synergistic modulations of both nominal cutting speed and depth-of-cut (DOC) in Elliptical Vibration texturing are applied to provide concave-convex topography and structural coloration. A new rendering strategy for the face turning configuration with an equidistant spiral tool path has been presented to improve the image rendering efficiency over the raster scan tool path. In addition, different from the conventional Elliptical Vibration texturing, the nominal DOC dynamically changes pixel by pixel in the proposed new process. In order to identify the effects of DOC and Elliptical Vibration trajectories on the surface quality and fidelity of generated gratings, grooving experiments have been conducted on brass samples to further the understanding of nonlinear tool-workpiece interactions. Finally, both raster scan and face turning tests have been performed on an ultraprecision platform with optimized process parameters. Structurally colored basso-relievos with high quality have been successfully demonstrated using the proposed fabrication method.
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Vibration analysis and development of an ultrasonic Elliptical Vibration tool based on a portal frame structure
Precision Engineering-journal of The International Societies for Precision Engineering and Nanotechnology, 2017Co-Authors: Yang Yang, Shiming Gao, Keyu Chen, Yayue Pan, Ping GuoAbstract:Abstract An ultrasonic Elliptical Vibration tool utilizing the coupled resonant Vibration modes is the key component in the Elliptical Vibration cutting/texturing process, which has been successfully applied to ultra-precision machining and surface texturing. In this paper, an analytical approach is proposed to analyze the resonant frequency and mode shapes of the ultrasonic Elliptical Vibration tool. A new design of ultrasonic Elliptical Vibration tool based on a portal frame structure is presented and analyzed using the proposed model. The model assumes Euler-Bernoulli beams and utilizes the transfer matrix technique to reduce the order of the system to only six variables. The model can be utilized to provide a systematic approach for an optimal design and be extended to dynamic analysis of the tool for study of machine-tool dynamics. Finite element simulation results as well as experimental data based on the prototype design are presented to verify the model. An application of the proposed tool is also demonstrated in machining micro/nano-structured surfaces for structural coloration.
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Turning of Microgrooves Both With and Without Aid of Ultrasonic Elliptical Vibration
Materials and Manufacturing Processes, 2015Co-Authors: Chen Zhang, Ping Guo, Kornel F. EhmannAbstract:Microgroove, as a form of surface texturing, has a wide array of industrial applications. However, the use of conventional methods to machine microgrooves leads to a number of problems including large burrs, high cutting forces, and poor machining quality. In this paper, ultrasonic Elliptical Vibration cutting is used to assist microgrooves turning on cylindrical workpiece surfaces. The Elliptical locus in the cutting process is generated by a newly designed 2D resonant ultrasonic vibrator. A series of microgrooves cutting experiments without and with the ultrasonic Elliptical Vibration-assistance is performed to verify the effects of the ultrasonic Elliptical Vibrations as compared to the ordinary cutting method. The generated cutting forces, burr suppression action, and microgroove surface quality are compared for the two classes of processes. Comparison results show the effectiveness of Elliptical Vibration-assisted microgroove cutting in reducing cutting forces and improving microgrooves machining qua...