Vibration Assisted Machining: Fundamentals, Modelling and Applications

220 Pages·2023·11.33 MB·English

by  Wei Bai, Yuan Gao, Ronglei Sun

Research on Intelligent Manufacturing
Wei Bai 
Yuan Gao 
Ronglei Sun
Vibration Assisted
Machining
Fundamentals, Modelling
and Applications
Research on Intelligent Manufacturing
Editors-in-Chief
Han Ding, Huazhong University of Science and Technology, Wuhan, Hubei, China
Ronglei Sun, Huazhong University of Science and Technology, Wuhan, Hubei,
China
Series Editors
Kok-Meng Lee, Georgia Institute of Technology, Atlanta, GA, USA
Cheng’en Wang, School of Mechanical Engineering, Shanghai Jiao Tong
University, Shanghai, China
Yongchun Fang, College of Computer and Control Engineering, Nankai University,
Tianjin, China
Yusheng Shi, School of Materials Science and Engineering, Huazhong University
of Science and Technology, Wuhan, Hubei, China
Hong Qiao, Institute of Automation, Chinese Academy of Sciences, Beijing, China
Shudong Sun, School of Mechanical Engineering, Northwestern Polytechnical
University, Xi’an, Shaanxi, China
Zhijiang Du, State Key Laboratory of Robotics and System, Harbin Institute of
Technology, Harbin, Heilongjiang, China
Dinghua Zhang, School of Mechanical Engineering, Northwestern Polytechnical
University, Xi’an, Shaanxi, China
Xianming Zhang, School of Mechanical and Automotive Engineering, South China
University of Technology, Guangzhou, Guangdong, China
Dapeng Fan, College of Mechatronic Engineering and Automation, National
University of Defense Technology, Changsha, Hunan, China
Xinjian Gu, School of Mechanical Engineering, Zhejiang University, Hangzhou,
Zhejiang, China
Bo Tao, School of Mechanical Science and Engineering, Huazhong University of
Science and Technology, Wuhan, Hubei, China
Jianda Han, College of Artificial Intelligence, Nankai University, Tianjin, China
Yongcheng Lin, College of Mechanical and Electrical Engineering, Central South
University, Changsha, Hunan, China
Zhenhua Xiong, School of Mechanical Engineering, Shanghai Jiao Tong
University, Shanghai, China
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· ·
Wei Bai Yuan Gao Ronglei Sun
Vibration Assisted
Machining
Fundamentals, Modelling and Applications
Wei Bai Yuan Gao
School of Mechanical Science Aerospace Research Institute of Materials
and Technology and Processing Technology
Huazhong University of Science Beijing, China
and Technology
Wuhan, China
School of Mechanical Engineering
and Electronic Information
China University of Geosciences
Wuhan, China
Ronglei Sun
School of Mechanical Science
and Technology
Huazhong University of Science
and Technology
Wuhan, China
ISSN 2523-3386 ISSN 2523-3394 (electronic)
Research on Intelligent Manufacturing
ISBN 978-981-19-9130-1 ISBN 978-981-19-9131-8 (eBook)
https://doi.org/10.1007/978-981-19-9131-8
Jointly published with Huazhong University of Science and Technology Press
The print edition is not for sale in China (Mainland). Customers from China (Mainland) please order the
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Preface
Efficient and high-quality manufacturing of difficult-to-machine materials has always
been a problem that plagues the scientific and industrial communities. Compared with
traditional manufacturing processes, energy field-assisted manufacturing technology
has become the forefront of the manufacturing field and an effective way to solve the
above problems. As an emerging typical energy field-assisted manufacturing tech-
nology, vibration assisted machining technology is becoming an advanced manufac-
turing technology favoured by academia and industry. Vibration assisted machining
technology drives the tool or workpiece to generate micron-scale periodic vibra-
tion through external energy, thereby changing the geometrical–mechanical–thermal
interaction mechanism between the tool and the workpiece, so as to achieve material
machinability better than conventional machining. Many scholars have studied the
theory and application of vibration assisted machining from different aspects and
produced a lot of achievements. The purpose of this book is to summarize the work
done by our team in the field of vibration assisted machining in recent years, hoping
to provide some reference for the scholars and engineers in related fields.
In the light of this, the proposed book covers the fundamentals, modelling and
applications of vibration assisted machining comprising 11 chapters. It begins with a
brief overview of the state of the art and perspectives on future research of vibration
assisted machining in Chap. 1. Chapter 2 introduces the classification, technolog-
ical advantages, device and system composition of vibration assisted machining.
The kinematics of vibration assisted cutting processes (e.g. ultrasonically assisted
cutting, modulation assisted cutting and elliptical vibration cutting) are investigated
in Chap. 3. The analytical models of cutting forces (Chap. 4), cutting temperature
(Chap. 5) and cutting stability (Chap. 6) in vibration assisted cutting are established.
To concern the machining quality, the surface topography and roughness (Chap. 7),
microstructural evolution (Chap. 8) and tool wear (Chap. 9) are investigated. In the
last part of the book, the aerospace and biomedical applications of vibration assisted
machining processes are presented in Chaps. 10 and 11, respectively.
v
vi Preface
The main work of this book is part of our work in the field of vibration assisted
machining in recent years, mainly completed by the editors of this book, Prof.
Wei Bai, Dr. Yuan Gao and Prof. Ronglei Sun. Also involved in the writing and
content research of this book are Prof. Jianfeng Xu, Prof. Vadim V. Silberschmidt,
Prof. Anish Roy, Prof. Naohiko Sugita, and Associate Prof. Jianguo Zhang, Prof.
Liming Shu, Prof. Jürgen Leopold, thanks to Dr. Dong Wang, Dr. Zhenglong
Fang, Mr. Zuohui Yang, Mr. Pengfei Pan, Prof. Satyam Suwas, Dr. Anuj Bisht
and other members who supported and assisted in the formation of this book.
Meanwhile, the research and writing of this book are funded by the National
Basic Research Programme of China (973 Programme) (No. 2013CB035805),
the China Scholar Council (CSC), the National Natural Science Foundation of
China (No. 52005199 and No. 42241149), the China Postdoctoral Science Foun-
dation (No. 2019M652629 and No. 2019TQ0107), the Shenzhen Fundamental
Research Programme of China (No. JCYJ20200109150425085), the Shenzhen
Science and Technology Programme of China (No. JSGG20201103100001004 and
No. JSGG20220831105800001) and the Knowledge Innovation Programme of
Wuhan-Basic Research (No. 2022010801010203).
Academia and industry have carried out a lot of research and applications on vibra-
tion assisted machining technology, and in the future, more scholars and engineers
will be attracted to research and promote the development of this technology. This
book only clarifies a small part of the theory and application of vibration assisted
machining, and there is still a lot of content that needs further research and improve-
ment. Feedback from readers on errors and omissions in the writing of this book is
also very welcome to help us make corrections and improvements in future possible
editions.
Wuhan, China Wei Bai
Beijing, China Yuan Gao
Wuhan, China Ronglei Sun
Contents
1 Introduction .................................................. 1
1.1 Outline of Vibration Assisted Machining .................... 1
1.2 The State of Art and Trend ................................ 3
References .................................................... 6
2 Fundamentals and System of Vibration Assisted Machining ....... 13
2.1 Types of Vibration Assisted Machining ...................... 13
2.1.1 Frequency-Based Classification ..................... 13
2.1.2 Direction-Based Classification ...................... 14
2.1.3 Dimension-Based Classification .................... 16
2.2 Benefits of Vibration Assisted Machining .................... 19
2.2.1 Cutting Forces .................................... 19
2.2.2 Surface Quality ................................... 20
2.2.3 Tool Wear ....................................... 21
2.2.4 Cutting Stability .................................. 22
2.3 System and Components of Vibration Assisted Machining ..... 23
2.3.1 Vibration Device ................................. 23
2.3.2 Vibration Generator ............................... 25
2.3.3 Vibration Transducer .............................. 25
2.4 Summary ............................................... 26
References .................................................... 27
3 Kinematics of Vibration Assisted Cutting ........................ 29
3.1 Introduction ............................................. 29
3.2 Kinematics of Ultrasonically Assisted Cutting ................ 30
3.2.1 Kinematics Characteristic .......................... 30
3.2.2 Relative Cutting Velocity .......................... 33
3.3 Kinematics of Modulation Assisted Cutting .................. 34
3.3.1 Kinematics Characteristic .......................... 34
3.3.2 Realization of Discrete Chip Formation .............. 36
3.3.3 Cutting Thickness and Cutting Angles ............... 38
3.4 Kinematics of Elliptical Vibration Cutting ................... 41
vii
viii Contents
3.5 Summary ............................................... 43
References .................................................... 43
4 Cutting Forces in Vibration Assisted Cutting .................... 45
4.1 Introduction ............................................. 45
4.2 Cutting Forces in Ultrasonically Assisted Cutting ............. 46
4.2.1 Shear Angle ...................................... 46
4.2.2 Tool-Chip Frictional Behaviour ..................... 47
4.2.3 Analytical Modelling and Parameter Prediction ....... 49
4.3 Cutting Forces in Modulation Assisted Cutting ............... 52
4.3.1 Force Modelling of Modulation Assisted Face
Turning ......................................... 52
4.3.2 Force Modelling for Reverse Cutting Phase ........... 55
4.3.3 Identification and Validation of the Model
Parameters ....................................... 56
4.3.4 Validation of the Analytical Force Model ............. 56
4.4 Cutting Forces in Elliptical Vibration Cutting ................. 66
4.4.1 Analysis of the Force Model ........................ 66
4.4.2 Experiments and Discussions ....................... 72
4.5 Summary ............................................... 74
References .................................................... 75
5 Temperature in Vibration Assisted Cutting ...................... 77
5.1 Introduction ............................................. 77
5.2 Analytical Modelling of Tool Temperature ................... 78
5.2.1 Geometric Simplification and Temperature
Modeling of Tool ................................. 78
5.2.2 Calculation of Tool Temperature .................... 82
5.3 Numerical Modelling of Tool Temperature ................... 86
5.3.1 Simulation of Tool Heat Conduction with Abaqus ..... 86
5.3.2 Simulation of Orthogonal Cutting
with AdvantEdge ................................. 89
5.4 Experimental Investigations of Tool Temperature ............. 95
5.5 Summary ............................................... 96
References .................................................... 96
6 Cutting Stability in Vibration Assisted Cutting ................... 99
6.1 Introduction ............................................. 99
6.2 Cutting Stability in Orthogonal Cutting ...................... 100
6.2.1 Free Vibrations in the Machine-Tool System .......... 101
6.2.2 Regenerative Chatter Phenomenon .................. 103
6.3 Cutting Stability in Vibration Assisted Cutting ................ 106
6.3.1 Analytical Modeling of Cutting Stability ............. 106
6.3.2 Stability Analysis for Vibration Assisted Cutting ...... 107
6.3.3 Case Study and Verification by Time-Domain
Simulation ....................................... 109
Contents ix
6.4 Summary ............................................... 111
References .................................................... 111
7 Surface Topography and Roughness in Vibration Assisted
Machining .................................................... 113
7.1 Introduction ............................................. 113
7.2 Analysis of Surface Topography and Roughness .............. 114
7.2.1 Surface Topography and Roughness Modeling ........ 114
7.2.2 Analysis of the Effect of Modulation Conditions ...... 125
7.3 Experimental Investigations of Surface Topography
and Roughness ........................................... 128
7.3.1 Qualitative Experimental Verification ................ 128
7.3.2 Quantitative Experimental Verification ............... 130
7.4 Summary ............................................... 132
References .................................................... 132
8 Microstructural Evolution in Vibration Assisted Cutting .......... 135
8.1 Introduction ............................................. 135
8.2 Numerical Models of Microstructural Evolution .............. 137
8.3 Microstructural Evolution of Machined Surface ............... 141
8.3.1 Status Tracking of Machined Surface ................ 141
8.3.2 Numerical Results for Microstructural Evolution ...... 141
8.3.3 Experimental Results for Machined Surface .......... 143
8.4 Microstructural Evolution of Chip .......................... 147
8.4.1 Status Tracking of Chip ............................ 147
8.4.2 Numerical Results for Microstructural Evolution ...... 148
8.4.3 Experimental Results for Chip ...................... 149
8.5 Summary ............................................... 152
References .................................................... 152
9 Tool Wear in Vibration Assisted Machining ...................... 155
9.1 Introduction ............................................. 155
9.2 Tool Wear in Ultrasonically Assisted Machining .............. 157
9.2.1 Machining Experiment Material and Setup ........... 157
9.2.2 Assessment of Tool Wear .......................... 159
9.3 Tool Wear in Modulation Assisted Machining ................ 164
9.3.1 Microscopic Observation of Tool Wear ............... 164
9.3.2 Analysis the Influencing Factors of Tool Wear Rate .... 168
9.3.3 Effect of Temperature on Tool Wear Rate ............. 171
9.4 Summary ............................................... 173
References .................................................... 173
10 Aerospace Applications of Vibration Assisted Machining .......... 175
10.1 Introduction ............................................. 175
10.2 Machining of Aerospace-Grade Inconel Alloys ............... 177
10.2.1 Experiment Setup ................................. 177
10.2.2 Workpiece Material ............................... 177