Vibration Assisted Machining
Theory, Modelling and Applications
1st Edition
Published on 14. January 2021
Book
Hardback
225 pages
978-1-119-50635-5 (ISBN)
Description
Vibration Assisted Machining: Theory, Modelling and Applications comprehensively covers all key aspects of vibration assisted machining such as cutting kinematics and dynamics, effect of workpiece materials and wear of cutting tools and applications. Case studies with detailed guidance on design, modelling and tests of VAM systems, and machining experiment method are included and state-of-the-art research development on cutting force modelling and surface texture generation is considered.
Vibration Assisted Machining: Theory, Modelling and Applications provides engineering students, researchers, and manufacturing engineers with the fundamentals of vibration assisted machining and methodologies for developing and implementing such technology to solve practical industry problems.
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02/2021
1st Edition
Wiley-ISTE
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E-Book
02/2021
1st Edition
Wiley-ISTE
€125.99
Available for download
Persons
Dr. Dehong Huo is a senior lecturer in precision engineering in the School of Engineering at 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. Dr. Huo is member of IET and Euspen, Fellow of Higher Education Academy, and EPSRC College member.
Dr. Wanqun Chen is an Associate Professor at Harbin Institute of Technology, China.
Content
Preface
Chapter 1 Introduction to vibration assisted machining technology 6
1. Overview of vibration assisted machining technology 6
1.1 Background 6
1.2 History and development of vibration assisted machining 7
2. Vibration assisted machining process 8
2.1 Vibration assisted milling 8
2.2 Vibration assisted drilling 9
2.3 Vibration assisted turning 10
2.4 Vibration assisted grinding 11
2.5 Vibration assisted polishing 12
2.6 Other vibration assisted machining processes 12
3. Applications and benefits of vibration assisted machining 13
3.1 Ductile mode cutting of brittle materials 13
3.2 Cutting force reduction 14
3.3 Burrs suppression 14
3.4 Tool life extension 15
3.5 Machining accuracy and surface quality improvement 16
3.6 Surface texture generation 16
4. Future trend of vibration assisted machining 19
Chapter 2 Review of vibration systems 27
1. Introduction 27
2. Actuators 28
2.1 Piezoelectric actuators 28
2.2 Magnetostrictive actuators 28
3. Transmission mechanisms 29
4. Drive and control 29
5. Vibration assisted machining systems 30
5.1 Resonant vibration systems 30
5.2 Non-resonant vibration system 38
6. Future perspectives 45
7. Concluding remarks 46
Chapter 3 Vibration system design and implementation 57
1. Introduction 57
2. Resonant vibration system design 58
2.1 Composition of the resonance system and its working principle 58
2.2 Summary of design steps 58
2.3 Power calculation 59
2.4 Ultrasonic transducer design 62
2.5 Horn design 67
2.6 Design optimization 68
3. Non-resonant vibration system design 70
3.1 Modelling of flexible mechanism 70
3.2 Compliance modelling of flexure hinges based on the matrix method 71
3.3 Compliance modelling of flexure mechanism 74
3.4 Compliance modelling of the 2 DOF vibration stage 75
3.5 Dynamic analysis of the vibration stage 77
3.6 Finite element analysis of the mechanism 78
3.7 Piezoelectric actuators selection 81
3.8 Control system design 81
3.9 Hardware selection 83
3.10 Layout of the control system 84
4. Concluding remarks 85
Chapter 4 Kinemics analysis of vibration assisted machining 91
1. Introduction 91
2. Kinematics of vibration assisted turning 92
2.1 TWS in 1D VAM turning 94
2.2 TWS in 2D VAM turning 97
3. Kinematics of vibration assisted milling 99
3.1 Types of TWS in VAMilling 101
3.2 Requirements of TWS 103
4. Finite element simulation of vibration assisted milling 111
5. Concluding remarks 115
Chapter 5 Surface topography simulation technology for vibration assisted machining 117
1. Introduction 117
2. Surface generation modelling in vibration assisted milling 123
2.1 Cutter edge modelling 124
2.2 Kinemics analysis of vibration assisted milling 125
2.3 Homogeneous matrix transformation 126
2.4 Surface generation 134
2.5 Surface generation simulation 135
3. Vibration-assisted milling experiments 138
4. Discussion and analysis 141
4.1 The influence of the vibration parameters on the surface wettability 141
4.2 Tool wear analysis 143
5. Concluding remarks 144
Chapter 6 Finite element modelling and analysis of vibration assisted machining 149
1. Introduction 149
2. Size effect mechanism in vibration assisted micro milling 152
2.1 FE model setup 154
2.2 Simulation study on size effect in vibration assisted machining 156
3. Materials removal mechanism in vibration assisted machining 158
3.1 Shear angle 158
3.2 Simulation study on chip formation in vibration assisted machining 159
3.3 Characteristics of simulated cutting force and von-Mises stress in vibration assisted micro milling 162
4. Burr control in vibration assisted milling 165
4.1 Kinematics analysis 166
4.2 Finite element simulation 168
5. Verification of simulation models 169
5.1 Tool wear and chip formation 170
5.2 Burr formation 171
6. Concluding remarks 172
Chapter 7 Investigation of the modelling of cutting force in vibration assisted machining 176
1. Introduction 176
2. Elliptical vibration cutting 177
2.1 Elliptical tool path dimensions 177
2.2 Analysis and Modelling of EVC Process 178
2.3 Validation of the proposed method 184
3. Vibration assisted milling 185
3.1 Tool-workpiece separation in vibration assisted milling 186
3.2 Verification of tool-workpiece separation 190
3.3 Cutting force modelling of VAMILL 195
3.4 Discussion of simulation results discussion and experiments 199
4. Concluding remarks 206
Chapter 8 Tool wear and burr formation analysis in vibration assisted machining 208
1. Introduction 208
2. Tool wear 208
2.1 Classification of tool wear 208
2.2 Wear mechanism and influencing factors 210
2.3 Tool wear reduction in vibration assisted machining 212
3. Burr formation 224
3.1 Burr formation and classification 225
3.2 Burr reduction in vibration assisted machining 226
3.3 Burr reduction in vibration assisted micro machining 228
4. Concluding remarks 232
4.1 Tool wear 232
4.2 Burr formation 232