Vibration Assisted Machining

Dr. Lu Zheng received his MSc and PhD in Mechanical Engineering from Newcastle University, UK in 2016 and 2020, respectively. He is currently a Lecturer at China Agricultural University. His research interests include cutting performance and functional surface generation in vibration assisted machining.Dr. Wanqun Chen received his PhD in mechanical engineering from Harbin Institute of Technology, China in 2014. Currently, he is an Associate Professor at Harbin Institute of Technology. His research interests include ultra-precision machining and vibration assisted machining. He has published more than 80 peer reviewed papers, contributed to three book chapters and holds six patents. Dr. Dehong Huo is currently a Senior Lecturer in Precision Engineering at the School of Engineering, Newcastle University, UK. Currently, his work in precision manufacturing is focused on precision/micro machining processes for hard-to-machine materials and hybrid manufacturing processes. He is the co-author of four books and more than 100 papers in international journals and conferences. He is the editor and reviewer of many international journals and is an organizer for several international scientific conferences.

• Preface xi1 Introduction to Vibration-Assisted Machining Technology 11.1 Overview of Vibration-Assisted Machining Technology 11.1.1 Background 11.1.2 History and Development of Vibration-Assisted Machining 21.2 Vibration-Assisted Machining Process 31.2.1 Vibration-Assisted Milling 31.2.2 Vibration-Assisted Drilling 31.2.3 Vibration-Assisted Turning 51.2.4 Vibration-Assisted Grinding 51.2.5 Vibration-Assisted Polishing 61.2.6 Other Vibration-Assisted Machining Processes 71.3 Applications and Benefits of Vibration-Assisted Machining 71.3.1 Ductile Mode Cutting of Brittle Materials 71.3.2 Cutting Force Reduction 81.3.3 Burr Suppression 81.3.4 Tool Life Extension 81.3.5 Machining Accuracy and Surface Quality Improvement 91.3.6 Surface Texture Generation 101.4 Future Trend of Vibration-Assisted Machining 10References 122 Review of Vibration Systems 172.1 Introduction 172.2 Actuators 182.2.1 Piezoelectric Actuators 182.2.2 Magnetostrictive Actuators 182.3 Transmission Mechanisms 182.4 Drive and Control 192.5 Vibration-Assisted Machining Systems 192.5.1 Resonant Vibration Systems 192.5.1.1 1D System 202.5.1.2 2D and 3D Systems 232.5.2 Nonresonant Vibration System 272.5.2.1 2D System 292.5.2.2 3D Systems 342.6 Future Perspectives 352.7 Concluding Remarks 36References 373 Vibration System Design and Implementation 453.1 Introduction 453.2 Resonant Vibration System Design 463.2.1 Composition of the Resonance System and Its Working Principle 463.2.2 Summary of Design Steps 463.2.3 Power Calculation 473.2.3.1 Analysis of Working Length Lpu 483.2.3.2 Analysis of Cutting Tool Pulse Force Fp 493.2.3.3 Calculation of Total Required Power 493.2.4 Ultrasonic Transducer Design 493.2.4.1 Piezoelectric Ceramic Selection 493.2.4.2 Calculation of Back Cover Size 513.2.4.3 Variable Cross-Sectional, One-Dimensional Longitudinal Vibration Wave Equation 513.2.4.4 Calculation of Size of Longitudinal Vibration Transducer Structure 533.2.5 Horn Design 533.2.6 Design Optimization 543.3 Nonresonant Vibration System Design 553.3.1 Modeling of Compliant Mechanism 563.3.2 Compliance Modeling of Flexure Hinges Based on the Matrix Method 563.3.3 Compliance Modeling of Flexure Mechanism 593.3.4 Compliance Modeling of the 2 DOF Vibration Stage 613.3.5 Dynamic Analysis of the Vibration Stage 623.3.6 Finite Element Analysis of the Mechanism 633.3.6.1 Structural Optimization 633.3.6.2 Static and Dynamic Performance Analysis 633.3.7 Piezoelectric Actuator Selection 653.3.8 Control System Design 663.3.8.1 Control Program Construction 663.3.9 Hardware Selection 663.3.10 Layout of the Control System 683.4 Concluding Remarks 68References 693.A Appendix 704 Kinematics Analysis of Vibration-Assisted Machining 734.1 Introduction 734.2 Kinematics of Vibration-Assisted Turning 744.2.1 TWS in 1D VAM Turning 754.2.2 TWS in 2D VAM Turning 784.3 Kinematics of Vibration-Assisted Milling 804.3.1 Types of TWS in VAMilling 814.3.1.1 Type I 814.3.1.2 Type II 824.3.1.3 Type III 824.3.2 Requirements of TWS 834.3.2.1 Type I Separation Requirements 834.3.2.2 Type II Separation Requirements 854.3.2.3 Type III Separation Requirements 874.4 Finite Element Simulation of Vibration-Assisted Milling 894.5 Conclusion 93References 935 Tool Wear and Burr Formation Analysis in Vibration-Assisted Machining 955.1 Introduction 955.2 Tool Wear 955.2.1 Classification of Tool Wear 955.2.2 Wear Mechanism and Influencing Factors 965.2.3 Tool Wear Reduction in Vibration-Assisted Machining 985.2.3.1 Mechanical Wear Suppression in 1D Vibration-Assisted Machining 985.2.3.2 Mechanical Wear Suppression in 2D Vibration-Assisted Machining 1015.2.3.3 Thermochemical Wear Suppression in Vibration-Assisted Machining 1025.2.3.4 Tool Wear Suppression in Vibration-Assisted Micromachining 1065.2.3.5 Effect of Vibration Parameters on Tool Wear 1075.3 Burr Formation 1085.4 Burr Formation and Classification 1095.5 Burr Reduction in Vibration Assisted Machining 1095.5.1 Burr Reduction in Vibration-Assisted Micromachining 1115.6 Concluding Remarks 1135.6.1 Tool Wear 1135.6.2 Burr Formation 115References 1156 Modeling of Cutting Force in Vibration-Assisted Machining 1196.1 Introduction 1196.2 Elliptical Vibration Cutting 1206.2.1 Elliptical Tool Path Dimensions 1206.2.2 Analysis and Modeling of EVC Process 1206.2.2.1 Analysis and Modeling of Tool Motion 1206.2.2.2 Modeling of Chip Geometric Feature 1206.2.2.3 Modeling of Transient Cutting Force 1246.2.3 Validation of the Proposed Method 1266.3 Vibration-Assisted Milling 1276.3.1 Tool–Workpiece Separation in Vibration Assisted Milling 1286.3.2 Verification of Tool–Workpiece Separation 1316.3.3 Cutting Force Modeling of VAMILL 1336.3.3.1 Instantaneous Uncut Thickness Model 1336.3.3.2 Cutting Force Modeling of VAMILL 1366.3.4 Discussion of Simulation Results and Experiments 1376.4 Concluding Remarks 143References 1437 Finite Element Modeling and Analysis of Vibration-Assisted Machining 1457.1 Introduction 1457.2 Size Effect Mechanism in Vibration-Assisted Micro-milling 1477.2.1 FE Model Setup 1487.2.2 Simulation Study on Size Effect in Vibration-Assisted Machining 1517.3 Materials Removal Mechanism in Vibration-Assisted Machining 1527.3.1 Shear Angle 1527.3.2 Simulation Study on Chip Formation in Vibration-Assisted Machining 1547.3.3 Characteristics of Simulated Cutting Force and von-Mises Stress in Vibration-Assisted Micro-milling 1567.4 Burr Control in Vibration-Assisted Milling 1587.4.1 Kinematics Analysis 1597.4.2 Finite Element Simulation 1607.5 Verification of Simulation Models 1617.5.1 Tool Wear and Chip Formation 1627.5.2 Burr Formation 1637.6 Concluding Remarks 164References 1648 Surface Topography Simulation Technology for Vibration-Assisted Machining 1678.1 Introduction 1678.2 Surface Generation Modeling in Vibration-Assisted Milling 1718.2.1 Cutter Edge Modeling 1728.2.2 Kinematics Analysis of Vibration-Assisted Milling 1738.2.3 Homogeneous Matrix Transformation 1748.2.3.1 Basic Theory of HMT 1748.2.3.2 Establishment of HTM in the End Milling Process 1748.2.3.3 HMT in VAMILL 1768.2.4 Surface Generation 1858.2.4.1 Surface Generation Simulation 1858.3 Vibration-Assisted Milling Experiments 1878.4 Discussion and Analysis 1878.4.1 The Influence of the Vibration Parameters on the Surface Wettability 1888.4.2 Tool Wear Analysis 1898.5 Concluding Remarks 189References 189Index 193