Vibration Assisted Machining Theory, Modelling and Applications

by Zheng, Lu; Chen, Wanqun; Huo, Dehong

• ISBN13: 9781119506355
• ISBN10: 1119506352
• Edition: 1st
• Format: Hardcover
• Copyright: 2021-02-16
• Publisher: Wiley-ASME Press Series

Summary

The first book to comprehensively address the theory, kinematic modelling, numerical simulation and applications of vibration assisted machining

Vibration Assisted Machining: Theory, Modelling and Applications covers all key aspects of vibration assisted machining, including cutting kinematics and dynamics, the effect of workpiece materials and wear of cutting tools. It also addresses practical applications for these techniques. Case studies provide detailed guidance on the design, modeling and testing of VAM systems. Experimental machining methods are also included, alongside considerations of state-of-the-art research developments on cutting force modeling and surface texture generation.

Advances in computational modelling, surface metrology and manufacturing science over the past few decades have led to tremendous benefits for industry. This is the first comprehensive book dedicated to design, modelling, simulation and integration of vibration assisted machining system and processes, enabling wider industrial application of the technology. This book enables engineering students and professionals in manufacturing to understand and implement the latest vibration assisted machining techniques. Highlights include:

• Comprehensive coverage of the theory, kinematics modelling, numerical simulation and applications of vibration assisted machining (VAM)
• Case studies with detailed guidance on design, modelling and testing of VAM systems, as well as experimental machining methods
• Discussion of state-of-the-art research developments on cutting force modelling and surface texture generation
• Coverage of the history of VAM, its current applications and future directions for the technology

Vibration Assisted Machining: Theory, Modelling and Applications provides engineering students, researchers, manufacturing engineers, production supervisors, tooling engineers, planning and application engineers and machine tool designers with the fundamentals of vibration assisted machining, along with methodologies for developing and implementing the technology to solve practical industry problems.

Author Biography

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.

Table of Contents

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