Journal articles: 'Ultrasonic machining process'

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Xiao, Qiang. "Research on the Machining Principle and Experinment of Ultrasonic Machining." Applied Mechanics and Materials 373-375 (August 2013): 1983–86. http://dx.doi.org/10.4028/www.scientific.net/amm.373-375.1983.

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Ultrasonic machining is a non-conventional machining process. Ultrasonic machining offers an effective alternative for ultra precision machining of hard and brittle materials due to its unique characteristics. This paper did a comprehensive analysis on ultrasonic machining mechanism in theory. The experiment compared this ultrasonic machining process with the common machining process in surface quality is done and the experimental result show that the smooth high quality surface can be obtained under ultrasonic machining.

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Yu, Jian Wu, Lucjan Dabrowski, Shao Hui Yin, and Zbigniew Lechniak. "Productivity of EDM Process Assisted by Ultrasonic Waves." Solid State Phenomena 175 (June 2011): 157–60. http://dx.doi.org/10.4028/www.scientific.net/ssp.175.157.

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Ultrasonic assisted electrical discharge machining (USEDM) is one of hybrid machining methods based on the EDM process. The effects of ultrasonic waves on EDM process were analyzed and the experimental investigation of productivity of steel induced by USEDM was reported. Results indicated that ultrasonic waves and cavitation played an important role in improving the flushing and machining efficiency during USEDM. And the material removal rate of EDM assisted by ultrasonic waves was improved greatly.

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Kimme, Simon, Nessma Hafez, Christian Titsch, Jonas Maximilian Werner, Andreas Nestler, and Welf-Guntram Drossel. "Close-to-process strain measurement in ultrasonic vibration-assisted turning." Journal of Sensors and Sensor Systems 8, no. 2 (September 24, 2019): 285–92. http://dx.doi.org/10.5194/jsss-8-285-2019.

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Abstract. The application of ultrasonic vibration assistance in machining offers many benefits over conventional machining. In some machining processes, like the generation of geometrically defined microstructures by cutting, the interaction of the system components and the machining process can be particularly crucial with respect to the production result. Monitoring of ultrasonic vibration-assisted machining in terms of the in-process measurement of frequency and amplitude is currently realized by measurement inside the actuator; thus, measurement is presently undertaken relatively far away from the cutting process. In this paper an in-process measurement set-up based on strain gauges positioned close to the cutting edges is presented. It is used to investigate the induced vibration in the ultrasonic horn. Experiments on machine samples with and without ultrasonic vibration assistance are performed using the in-process measurement set-up described. The results of the strain gauges are analysed in comparison to internal feedback signal and surface measurements. The experiments show the high sensitivity of the measurement set-up presented and a huge gain of information compared with the conventional measurement approach. This enables improved controllability of the excited mode shapes as well as in-process adjustment of the ultrasonic vibration frequency and amplitude for the manufacturing of defined microstructures.

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Ye, Hong-xian, Xu-yi Yang, Xiao-ping Hu, Bao-hua Yu, and Xi Kang. "Research on correlation model between transducer temperature and acoustic performance parameters of ultrasonic machining system." AIP Advances 12, no. 11 (November 1, 2022): 115303. http://dx.doi.org/10.1063/5.0124897.

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In the process of ultrasonic vibration cutting (UVC), the acoustic performance parameters of ultrasonic machining system change because of systems heating up and cutting loads. The changes of acoustic performance parameters will affect resonant frequency, impedance, and power match of the ultrasonic machining system, and stability of the amplitude of UVC system. It is hard to monitor the acoustic performance parameters online. Based on the analysis of the correlation mechanism between transducer temperature and acoustic performance parameters, the correlation models between transducer temperature and resonance frequency, static capacitance, and dynamic resistance of ultrasonic vibration machining system are established by curve regression analysis modeling method. The acoustic performance parameters of an ultrasonic vibration machining system are determined by transducer temperature using the correlation models. The effectiveness of the model is verified by experiments. It gives the information for the stability evaluation of the ultrasonic vibration machining process, the dynamic impedance matching of the ultrasonic machining system, and the power matching adjustment of the ultrasonic power supply.

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Wang, Z. Y., and K. P. Rajurkar. "Dynamic Analysis of the Ultrasonic Machining Process." Journal of Manufacturing Science and Engineering 118, no. 3 (August 1, 1996): 376–81. http://dx.doi.org/10.1115/1.2831039.

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This paper presents a dynamic analysis of the ultrasonic machining process based on impact mechanics. Equations representing the dynamic contact force and stresses caused by the impinging of abrasive grits on the work, are obtained by solving the three-dimensional equations of motion. The factors affecting the material removal rate have been studied. It is found that the theoretical estimates obtained from the dynamic model are in good agreement with the experimental results.

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Teimouri, R., H. Baseri, and Rasoul Moharami. "Multi-responses optimization of ultrasonic machining process." Journal of Intelligent Manufacturing 26, no. 4 (August 29, 2013): 745–53. http://dx.doi.org/10.1007/s10845-013-0831-1.

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Isobe, Hiromi, Yusuke Uehara, Keisuke Hara, Takashi Onuma, and Arata Mihara. "Experimental Verification of Machining Process of Ultrasonic Drilling." Key Engineering Materials 516 (June 2012): 275–80. http://dx.doi.org/10.4028/www.scientific.net/kem.516.275.

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Drill processing of difficult-to-cut materials such as ceramics, hardened steel, glass and heat-resistant steel is widely required in the industrial world. Furthermore the drilling process becomes more and more difficult in the case of hole diameters less than one millimetre. In order to achieve the requirements for the drilling process, ultrasonically assisted machining is applicable. Ultrasonic vibration assisted machining techniques are suitable for machining difficult-to-cut materials precisely. However, the cutting process of ultrasonic drilling has not been clarified. It is difficult to observe directly the effect of vibration. The aim of this study is to observe the dynamic, instantaneous and micro cutting process. In this report, a high-speed camera with a polarized device, which is appropriately arranged, realized the visualization of the process of ultrasonic drilling based on photoelastic analysis. For conventional drilling, the stress distribution diagram showed that the intensive stress occurred in limited areas under the chisel because the chisel edge of the drill produces large plastic deformation. On the other hand, the ultrasonic drilling produced spread stress distribution and a stress boundary far away from the chisel. The photoelastic analysis showed the explicit difference of drilling processes.

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Zeng, Wei Min, Xi Peng Xu, and Zhi Jian Pei. "Rotary Ultrasonic Machining of Advanced Ceramics." Materials Science Forum 532-533 (December 2006): 361–64. http://dx.doi.org/10.4028/www.scientific.net/msf.532-533.361.

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Rotary ultrasonic machining (RUM) is one of the cost-effective machining methods for advanced ceramics, which is a hybrid machining process that combines the material removal mechanisms of diamond grinding and ultrasonic machining (USM). This paper presents an overview of the investigations on RUM of advanced ceramics. The issues about the material removal mechanisms, process modeling, material removal rate, and tool wear in RUM are reviewed. Directions of future research on RUM are also presented.

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WANG, Jingsi, Keita SHIMADA, Masayoshi MIZUTANI, and Tsunemoto KURIYAGAWA. "B014 Influence of Process Parameters on Ultrasonic Machining using Smoothed Particle Hydrodynamics." Proceedings of International Conference on Leading Edge Manufacturing in 21st century : LEM21 2013.7 (2013): 214–19. http://dx.doi.org/10.1299/jsmelem.2013.7.214.

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Praneetpongrung, Chaiya, Yasushi Fukuzawa, and Shigeru Nagasawa. "Effects of Combined Ultrasonic Vibration during the Sinking EDM Process for Cemented Carbide." Advanced Materials Research 76-78 (June 2009): 657–63. http://dx.doi.org/10.4028/www.scientific.net/amr.76-78.657.

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In recent years, to improve the electrical discharge machining properties, several trials have been applied with the ultrasonic vibration system which was combined on the sinking electrical discharge machine. In this paper, the effects of the ultrasonic vibration were investigated with the designed sinking EDM machine. Some experimental parameters of tool electrode polarity, rotational workpiece speed and directions were examined during the sinking EDM process on the cemented carbide material of G5. Material removal rate, electrode wear ratio and surface roughness were estimated as the machining properties under finishing machining conditions. The experiments were carried out on ultrasonic longitudinal frequency 59 kHz and electrode spindle till 1,000 rpm. Two rotational apparatuses were used simultaneously on the opposite rotational direction during discharge machining. The discharge conditions were estimated with the waveforms analysis. As the results, the EDM device system which was combined ultrasonic vibration, improved the material removal rate and surface roughness of the EDMed workpiece.

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Zhang, Qin He, Ru Du, Jian Hua Zhang, J. Y. Yang, and Sheng Feng Ren. "The Mechanism of Ultrasonic Vibration Improving MRR in UEDM in Gas." Materials Science Forum 471-472 (December 2004): 741–45. http://dx.doi.org/10.4028/www.scientific.net/msf.471-472.741.

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A new machining method, ultrasonic vibration aided electrical discharge machining (UEDM) in gas, is proposed in this paper. It is shown that electrical discharge machining with ultrasonic vibration aid can be achieved well in gas medium. In the process of UEDM in gas, the tool electrode is formed to be thin-walled pipe, high pressure gas medium is supplied from inside, and ultrasonic vibration is applied to workpiece. The property of ultrasonic is introduced. The same to other sound waves, ultrasonic have the characteristics of reflecting, refracting, intervening and resonance. The mechanism of elastic pole keeping in resonance with ultrasonic transferring from one end to the other end is explained with characteristics of ultrasonic. During the process of UEDM in gas, ultrasonic vibration of workpiece can improve the machining process. The theories of ultrasonic vibration increasing materials removal rate (MRR) are introduced. One theory is that the adhere strength between the metallic liquid drops and workpiece is not enough for the accelerative vibration, so metallic liquid drops will be ejected off easily. Another theory is that ultrasonic vibration increases the number of the effective discharge.

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Liu, Yu, Hao Chang, Wenchao Zhang, Fujian Ma, Zhihua Sha, and Shengfang Zhang. "A Simulation Study of Debris Removal Process in Ultrasonic Vibration Assisted Electrical Discharge Machining (EDM) of Deep Holes †." Micromachines 9, no. 8 (July 30, 2018): 378. http://dx.doi.org/10.3390/mi9080378.

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When machining a small hole with high aspect ratio in EDM, it is hard for the flushing liquid entering the bottom gap and the debris could hardly be removed, which results in the accumulation of debris and affects the machining efficiency and machining accuracy. The assisted ultrasonic vibration can improve the removal of debris in the gap. Based on dynamics simulation software, Fluent, a three-dimensional (3D) model of debris movement in the gap flow field of EDM small hole machining assisted with side flushing and ultrasonic vibration is established in this paper. The laws of different amplitudes and frequencies and different aspect ratios on debris distribution and movement are quantitatively analyzed. The motion height of debris was observed under different conditions. The research results show that periodic ultrasonic vibration can promote the movement of debris, which is beneficial to the removal of debris in the machining gap. When compared to traditional small hole machining in EDM, the debris in the machining gap were greatly reduced, which ensures the stability of the machining process and improves the machining efficiency.

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Li, Li, Dong Wang, Zong Wei Niu, Zhi Yong Li, and Guang Ming Yuan. "Ultrasonic Machining Aided Tool Rotation of Sintered NdFeB Magnet." Key Engineering Materials 359-360 (November 2007): 420–24. http://dx.doi.org/10.4028/www.scientific.net/kem.359-360.420.

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A new kind of ultrasonic machining method named ultrasonic machining aided tool rotation is proposed for sintered NdFeB permanent magnet. In the process abrasive slurry enters the machining area through holes in the rotary tool which can assure the grains easily enter the machining surface slurry. Its machining mechanisms are studied and material removal model is developed. Experimental research was carried out on self-made equipment. Experimental results were accordance with the developed model. It is proved that this new kind of ultrasonic machining technology is suitable to machine deep hole for sintered NdFeB material.

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Pa, Pai Shan. "Design of Synchronous Processes of Rolling-Leveling and Ultrasonic Electrochemical Finishing of Holes." Advanced Materials Research 83-86 (December 2009): 785–92. http://dx.doi.org/10.4028/www.scientific.net/amr.83-86.785.

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A new finishing method of holes that uses an effective electrode and a nonconductive roller to execute the design of synchronous processes of ultrasonic electrochemical finishing and rolling-leveling is investigated. The submitted processes can be used among the traditional techniques of various holes machining. Through simple equipment attachment, ultrasonic electrochemical finishing and rolling-leveling can follow to execute the finishing process on the same machine. Among the factors affecting finishing processes, the performance of rolling-leveling combined with ultrasonic electrochemical finishing is primarily discussed. In the experiment, the electrode is used with continuous and pulsed direct current. The controlled factors include roller material, roller geometry, chemical composition and concentration of the electrolyte, and flow rate of electrolytes. The experimental parameters are frequency and power level of ultrasonics, feed rate of electrode and roller, rotational speed of the finish-tool, die material, electrical current rating, and pulsed period. The design of the synchronous processes through rolling-leveling is the most influential parameter in this study. An adequate finish-tool rotational speed produces better finishing. The average effect of the ultrasonic is better than the pulsed current while the machining time needs not to be prolonged by the off-time. An effective and low-cost finishing process through the ultrasonic electrochemical finishing and using the rolling-leveling assistance after the process of traditional holes machining make the surface of the holes smooth and bright is presented.

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Nad, Milan, and Lenka Cicmancova. "Effect of Shape Parameters on the Modal Properties of Stepped Ultrasonic Concentrator." Applied Mechanics and Materials 309 (February 2013): 43–49. http://dx.doi.org/10.4028/www.scientific.net/amm.309.43.

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mproving of cutting process is one of the most important requirements that are expected from the machining methods in the recent years. In some machining processes, the positive effect of ultrasonic waves to improve the cutting process is used. The cutting process efficiency depends on the structure of excitation system which generates ultrasonic waves. One of the most important elements of this system is the ultrasonic waveguide. The role of waveguide is the transfer of ultrasonic vibration energy from ultrasonic transducer to the tool cutting edge interacting with the workpiece (ultrasonic assisted machining-UAM). The UAM system performance depends on well-designed ultrasonic waveguide. The most important aspects of waveguide design are a resonant frequency, amplification factor and the determination of waveguide resonant wavelength - usually integer multiple of half wavelength. The effect of geometrical parameters of stepped waveguide on dynamical properties is presented in this paper.

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Zheng, Jian Xin, and Jia Wen Xu. "Basic Experimental Research on the NC-Contour Evolution Ultrasonic Assisted Grinding Ceramic Blade Surface." Key Engineering Materials 359-360 (November 2007): 369–273. http://dx.doi.org/10.4028/www.scientific.net/kem.359-360.369.

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Ultrasonic machining is a practical process for advanced ceramic machining. Usually, ceramics with complex surfaces are machined with two common ultrasonic assisted contour machining methods, which may be classified as surface/point contact machining mode. While these methods are not suitable to machine some complex surfaces such as blade surface, so an ultrasonic assisted contour machining method using a simple shaped diamond grinding wheel to machine ceramic blade surface is presented, which is named as Numerical Control-Contour Evolution Ultrasonic Assisted Grinding (NC-CEUAG) method. In the NC-CEUAG process, the contour evolution motion of the grinding wheel is controlled by the NC system and the blade surface is the enveloping surface formed by the grinding wheel’ cutting edges when they cut into the ceramic specimen. In this paper, the relative motion between the grinding wheel and the specimen in the process of NC-CEUAG ceramic blade surface is analyzed. The mathematical models of ruled surfaces are constructed. The ceramic blades with ruled surface are machined with selected machining parameters on the retrofitting NC-CEUAG machine tool.

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Li, Xiaokun, Yuankai Ren, Zhiyuan Wei, and Yong Liu. "Development of Ultrasonic Vibration Assisted Micro Electrochemical Discharge Machining Tool." Recent Patents on Mechanical Engineering 12, no. 4 (December 26, 2019): 313–25. http://dx.doi.org/10.2174/2212797612666190808101736.

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Background: The fabrication of microstructures with high machining quality is always difficult when it is concerned with non-conductive hard and brittle materials such as glass and engineering ceramics. It is reported in related papers and patents that Electrochemical Discharge Machining (ECDM) process is a good choice for machining non-conductive, hard and brittle materials. However, the machining performance of ECDM process, especially in the aspect of geometric accuracy and surface quality, needs to be greatly improved. Objective: The purpose of this study was to improve the machining quality of conventional ECDM process by introducing ultrasonic vibration to ECDM process, develop an Ultrasonic Vibration Assisted Micro Electrochemical Discharge Machining (UAECDM) tool, and investigate the improvements of the machining performance by means of comparative experiments. Methods: Firstly, the machining principle of UAECDM was investigated, and the effects of ultrasonic vibration are discussed with the analysis of the micro process. Secondly, the hardware system, which consists of a machine tool body, XY and Z axes, an ultrasonic spindle system and motion control system, was established; and the software system was developed based on the analysis of the overall workflow of the machining process. Finally, comparative experiments, including ECDM drilling, UAECDM drilling, ECDM milling and UAECDM milling, were carried out to reveal the improvements of the machining quality. Results: In the UAECDM group, a micro-hole with the inlet diameter of 133.2µm as well as the 3 × 3 array of micro holes was fabricated on the glass workpiece with 300µm thickness, and a microgroove with the width of 119.2µm was successfully milled on the glass workpiece. It is shown in both microscopic photographs and optical measurements that the microstructures fabricated by UAECDM have better machining quality compared with similar microstructures fabricated by ECDM. Conclusion: Based on comparative experiments and discussions of the results, it has been proved that the machine tool can meet the requirement of the ultrasonic vibration-assisted micro electrochemical discharge machining and can improve the geometric accuracy and surface quality significantly.

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Hu, Chen, and Yongwei Zhu. "System Design and Mechanism Study of Ultrasonic-Assisted Electrochemical Grinding for Hard and Tough Materials." Processes 11, no. 6 (June 7, 2023): 1743. http://dx.doi.org/10.3390/pr11061743.

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In this study, an ultrasonic-assisted electrochemical grinding (UAECG) system was designed to improve the low efficiency and tool wear in conventional grinding of hard and tough materials. In this system, multiple-field energy consisting of ultrasonic, electrochemical and mechanical grinding was used. The processing mechanism was investigated to determine the interaction mechanism between ultrasonic, grinding and electrochemical processing. The established theoretical model showed that the processing efficiency was affected by the ultrasonic amplitude, ultrasonic frequency, electrolyte conductivity and other parameters. In verifying the feasibility of UAECG machining and the effect of machining elements on machining, a series of corresponding machining experiments was conducted. Experiments showed that the machining efficiency can be improved by machining through the UAECG system. The material removal rate of W18Cr4V machining was 2.7 times higher than that of conventional grinding and 1.7 times higher than UAG. The processing efficiency of YT15 was increased by 3.2 times when the processing voltage increased from 2 to 6 V. The surface shape and roughness were also affected by these parameters. The surface roughness of the SiCp/Al workpiece reached the best level at 4 V as the machining voltage increased from 2 to 6 V. However, the surface roughness increased significantly when the voltage increased to 6 V. Thus, parameters such as machining voltage must be optimised for efficient and precise machining in practice.

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Sabyrov, Nurbol, M. Jahan, Azat Bilal, and Asma Perveen. "Ultrasonic Vibration Assisted Electro-Discharge Machining (EDM)—An Overview." Materials 12, no. 3 (February 10, 2019): 522. http://dx.doi.org/10.3390/ma12030522.

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Many of the industrial processes, including material removal operation for shape generation on the surface of material, exploit the assistance of ultrasonic vibrations. This trend of using ultrasonic vibration in order to improve the process performance is becoming more and more prominent recently. One of the significant applications of this ultrasonic vibration is in the industrial processes such as Electro-discharge machining (EDM), where ultrasonic vibration (UV) is inserted as a medium for enhancing the process performance. Mostly ultrasonic vibration is applied along with the EDM process to increase the efficiency of the process through debris cleansing from the sparking gap. There have been significant changes in ultrasonic assisted technology during the past years. Due to its inherent advantages, ultrasonic assistance infiltrated in different areas of EDM, such as wire cut EDM, micro EDM and die sinking EDM. This article presents an overview of ultrasonic vibration applications in electric discharge machining. This review provides information about modes of UV application, impacts on parameters of performance, optimization and process designing on difficult-to-cut materials. On the bases of available research works on ultrasonic vibration assisted EDM, current challenges and future research direction to improve the process capabilities are identified. Literature suggested improved material removal rate (MRR), increased surface roughness (SR) and tool wear ratio (TWR) due to the application of ultrasonic vibration assisted EDM. However, tool wear and surface roughness can be lessened with the addition of carbon nanofiber along with ultrasonic vibration. Moreover, the application of ultrasonic vibration to both tool and workpiece results in higher MRR compared to its application to single electrode.

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Zeng, Wei Min, Zhi Chao Li, Xi Peng Xu, Zhi Jian Pei, Ju Dong Liu, and Jun Pi. "Experimental Investigation of Intermittent Rotary Ultrasonic Machining." Key Engineering Materials 359-360 (November 2007): 425–30. http://dx.doi.org/10.4028/www.scientific.net/kem.359-360.425.

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Rotary ultrasonic machining (RUM) is considered as an effective machining method, which has been utilized to machine hard and brittle materials such as advanced ceramics. In order to improve the hole wall surface quality during RUM, it is important to wash away swarf in the gap between the tool and the workpiece as fast as possible. In this paper, a new machine process – intermittent rotary ultrasonic machining (IRUM) – is introduced for the first time. The cutting force, surface roughness and coolant flow rate in conventional rotary ultrasonic machining (CRUM) process and IRUM process are compared. It is found that compared with CRUM, the output coolant flow rate could be increased significantly by using the IRUM method. It is also found that the surface roughness of workpiece can be improved significantly in IRUM.

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Ichikawa, Tomohiko, and Wataru Natsu. "Study on Machining Characteristics of Ultrasonic Vibration Assisted Micro-EDM." Applied Mechanics and Materials 217-219 (November 2012): 2163–66. http://dx.doi.org/10.4028/www.scientific.net/amm.217-219.2163.

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The existence of debris in the inter-electrode area in micro-EDM interrupts the machining process. Applying ultrasonic vibration to the machining fluid helps circulate the machining fluid and remove the debris from the gap area, and thus reduce short-circuits and abnormal discharges. In this study, the effect of applying ultrasonic vibration to machining fluid in micro-EDM was experimentally investigated. It was found that a significant increase in the machining speed was realized by applying ultrasonic vibration. Also, with the vibration of the machining fluid, micro-hole drilling with ultra-small discharge energy became possible.

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Lin, Yan Cherng, Han Ming Chow, Hai Ping Tsui, and Yuan Feng Chen. "Study on Ultrasonic Vibration in Gas and Optimization of a Novel Process of EDM." Advanced Materials Research 675 (March 2013): 365–69. http://dx.doi.org/10.4028/www.scientific.net/amr.675.365.

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The aim of this study is to investigate the machining characteristics of ultrasonic vibration assisted electrical discharge machining (EDM) process using gas media as the dielectric fluids. The process parameters were designed based on Taguchi method to conduct the experimental works. The main process parameters such as machining polarity, peak current, pulse duration, air pressure, working time, and servo reference voltage were chosen to determine their effects on machining performance in terms of material removal rate and surface roughness for SKD 61 tool steels. The experimental response values were transferred to signal-to-noise (S/N) ratios, and then the significant machining parameters associated with the machining performance were examined by analysis of variance (ANOVA). Therefore, the technique of ultrasonic vibration assisted EDM process in gas media was established with the concerning features related to environmentally friendly, high efficiency, and high machining quality to fit the demands of modern manufacturing applications.

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Wdowik, Roman, Marek Magdziak, and Janusz Porzycki. "Measurements of Surface Roughness in Ultrasonic Assisted Grinding of Ceramic Materials." Applied Mechanics and Materials 627 (September 2014): 191–96. http://dx.doi.org/10.4028/www.scientific.net/amm.627.191.

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The paper presents the results of investigations regarding surface roughness measurements in ultrasonic assisted grinding of selected ZrO2 based ceramic material. There are different results, in the area of surface roughness measurements, presented in the literature. The entry data of hybrid machining process (e.g. grinding wheel type, feed, machining strategy or process variant) may influence these results. The analysis of literature encourages to take up the investigations of surface quality in ultrasonic assisted machining. These investigations may be performed for specific ceramic products and technological tasks which are commonly applied in ceramic machining processes. The knowledge about the machining of ceramic materials in different sintering states is very limited. Based on this finding, ultrasonic assisted and conventional machining processes of ZrO2 based ceramic material in different sintering states were investigated.

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Agapov, S. I., A. S. Prokhvatilov, A. F. Tolstyakov, and D. V. Zayarny. "PECULIARITIES OF THE PROCESS OF ULTRASONIC VIBRATION MASHINING." IZVESTIA VOLGOGRAD STATE TECHNICAL UNIVERSITY, no. 8(255) (August 31, 2021): 7–9. http://dx.doi.org/10.35211/1990-5297-2021-8-255-7-9.

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Dodun, Oana, Ema Panaite, Petru Duşa, Gheorghe Nagît, Margareta Coteată, and Laurentiu Slătineanu. "Axiomatic Design in Obtaining a Device for Ultrasonic Machining." MATEC Web of Conferences 223 (2018): 01021. http://dx.doi.org/10.1051/matecconf/201822301021.

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Ultrasonic abrasive cavitational machining is a nonconventional machining method applied to remove surfaces in workpieces made of brittle, hard, or non-conductive materials that cannot be efficiently machined by other classical or nonconventional machining methods. Among the factors that can affect the values of the parameters of technological interest for the ultrasonic machining process, the relative pressure between the ultrasonic tool and the workpiece surface to be machined could be considered. The main objective of the research presented in this paper was to analyze the possibilities of selecting the most convenient solution among many such available solutions to ensure the tool feed motion, when designing a device for achieving an ultrasonic drilling process. At present, this selection could be achieved by means of an optimal selection method. Taking into consideration some functional requirements of the device, the method of analytic hierarchy process and the axiomatic design theory were used to solve some problems met in the design process.

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Li, Zhi Yong, and Zong Wei Niu. "Process Parameter Optimization and Experimental Study of Micro-Holes in Electrochemical Micromachining Using Pulse Current." Advanced Materials Research 135 (October 2010): 293–97. http://dx.doi.org/10.4028/www.scientific.net/amr.135.293.

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Electrochemical micro-machining (EMM) has become one of the main machining methods for production of miniaturized parts and components. Utilizing a developed EMM set-up, sets of experiments have been carried out to investigate the influences of some of the predominant electrochemical process parameters such as pulse frequency, feed rate of tool, machining voltage and ultrasonic frequency on the machining accuracy of micro-holes. According to the present investigation, the most effective zone of pulse on time and ultrasonic frequency can be considered as 15-50μs and 26KHZ, respectively, which can gives a desirable machining accuracy for micro-holes. A machining voltage range of 6-10V can be commended to obtain high machining accuracy. From the micrographs of the machined micro-holes, it may be observed that a lower value of electrolyte concentration with moderate machining voltage and moderate value of pulse on time will produce more accurate shape of micro-holes.

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Zhang, Cheng Long, Ping Fa Feng, Zhi Jun Wu, and Ding Wen Yu. "A Mathematical Model for Predicting Cutting Force in Rotary Ultrasonic Drilling." Advanced Materials Research 433-440 (January 2012): 2034–41. http://dx.doi.org/10.4028/www.scientific.net/amr.433-440.2034.

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Rotary ultrasonic machining is a hybrid machining process that combines diamond grinding and ultrasonic machining. The mathematical predictive material removal rate models have been developed in rotary ultrasonic machining with a constant pressure. However, there is no report on mathematical predictive cutting force model in rotary ultrasonic drilling at a constant feedrate presently. Since cutting force can not only reflect the processing state, but also affect the machined surface quality, it is necessary to develop a mathematical model for predicting cutting force which can forecast the machining results. This paper presents a mathematical model to predict the cutting force in rotary ultrasonic machining. On the basis of this model, the relations between cutting force and controllable machining parameters are researched by numerical computation method. This paper also researches the influences of spindle speed and feedrate on cutting force by experiments. The results observed through the experiments agree well with the relations generated from the mathematical model, which verify the developed model.

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Srivastava, Arpit. "Developmental and Experimental Study of Rotary Ultrasonic drilling process." International Journal for Research in Applied Science and Engineering Technology 9, no. 8 (August 31, 2021): 2475–78. http://dx.doi.org/10.22214/ijraset.2021.37795.

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Abstract: The proper selection of machining conditions and machining parameter is an important aspect, before going to machine a brittle material by rotary ultrasonic drilling process Because these conditions will determine such important characteristics as; Material removal rate (MRR) and Surface roughness (SR). The purpose of this work is to determine the optimal values of machining parameters of rotary ultrasonic drilling process. The work has been based on the effect of three design factors: Tool feed rate, vibration frequency and grain size of abrasive particle on such characteristic like material removal rate (MRR). This work has been done by means of the technique of design of experiment (DOE), which provides us to perform the above-mentioned analysis with small number of experiments. In this work, a L9 orthogonal array is used to design the experiment. The adequate selection of machining parameters is very important in manufacturing system, because these parameters determine the surface quality and dimensional accuracy of the manufactured part. The optimal setting of the parameters are determined through experiments planned, conducted and analyzed using the Taguchi method. Keywords: RUSM, Material removal rate, Drilling, Taguchi method

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Cotargă, Elena Adina, Marcel Sabin Popa, Stefan Sattel, Dan Preja, Ovidiu Virgil Vereș, and Claudiu Ioan Jugrestan. "Ultrasonic Assisted Machining for Hard-to-Cut Materials." Applied Mechanics and Materials 809-810 (November 2015): 345–50. http://dx.doi.org/10.4028/www.scientific.net/amm.809-810.345.

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This study presents new machining types of advanced materials. Super alloys, ceramics and fiber reinforced plastics started being used on a large scale in the last period, this making necessary the development of new machines and machining processes. This paper describes different methods of ultrasonic machining and makes a comparison between them. By ultrasonic machining can be understood a process that involves axial vibrations with a high frequency and low amplitude, for improving the machining conditions like chip flute removal, tool wear and temperature reducing. In this paper, are presented three different ultrasonic machining methods. In the first one, the cutting process is made by abrasive slurry inserted between the tool and the workpiece, in the second one is made by a rotating diamond-brazed tool and in the last one is made by a special drill. This paper aims to study the current status in this field in order to make a research program through collaboration between the Technical University of Cluj-Napoca and the tool company Gühring KG by which to develop ultrasonic drilling.

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Zhang, Xu, Bin Lin, and Xue Song Han. "The Development of Physical Signal Measurement and Control in the Processing of Ultrasonic Machining." Applied Mechanics and Materials 37-38 (November 2010): 1442–47. http://dx.doi.org/10.4028/www.scientific.net/amm.37-38.1442.

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Ultrasonic machining (USM) is a mechanical material removal process used to erode holes and cavities in hard or brittle work pieces by using shaped tools, high-frequency mechanical motion, and an abrasive slurry. There are many physical signals in the ultrasonic machining which are related with the material removal rate, machining accuracy, and surface finish. So how to measure and control these signals with accuracy is very important. The aim of the paper is to summarize different kinds of physical signals and the methods of measuring and controlling them in ultrasonic machining.

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Zhang, Jian-Guo, Zhi-Li Long, Wen-Ju Ma, Guang-Hao Hu, and Yang-Min Li. "Electromechanical Dynamics Model of Ultrasonic Transducer in Ultrasonic Machining Based on Equivalent Circuit Approach." Sensors 19, no. 6 (March 21, 2019): 1405. http://dx.doi.org/10.3390/s19061405.

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Ultrasonic transducer is a piezoelectric actuator that converts AC electrical energy into ultrasonic mechanical vibration to accelerate the material removal rate of workpiece in rotary ultrasonic machining (RUM). In this study, an impedance model of the ultrasonic transducer is established by the electromechanical equivalent approach. The impedance model not only facilitates the structure design of the ultrasonic transducer, but also predicts the effects of different mechanical structural dimensions on the impedance characteristics of the ultrasonic transducer. Moreover, the effects of extension length of the machining tool and the tightening torque of the clamping nut on the impedance characteristics of the ultrasonic transducer are investigated. Finally, through experimental analysis, the impedance transfer function with external force is established to analyze the dynamic characteristics of machining process.

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Singh, Gurpreet, DR Prajapati, and PS Satsangi. "Optimization of μEDM process assisted with rotating magnetic pulling force and ultrasonic vibration." Proceedings of the Institution of Mechanical Engineers, Part E: Journal of Process Mechanical Engineering 235, no. 4 (January 12, 2021): 937–49. http://dx.doi.org/10.1177/0954408920984402.

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The micro-electrical discharge machining process is hindered by low material removal rate and low surface quality, which bound its capability. The assistance of ultrasonic vibration and magnetic pulling force in micro-electrical discharge machining helps to overcome this limitation and increase the stability of the machining process. In the present research, an attempt has been made on Taguchi based GRA optimization for µEDM assisted with ultrasonic vibration and magnetic pulling force while µEDM of SKD-5 die steel with the tubular copper electrode. The process parameters such as ultrasonic vibration, magnetic pulling force, tool rotation, energy and feed rate have been chosen as process variables. Material removal rate and taper of the feature have been selected as response measures. From the experimental study, it has been found that response output measures have been significantly improved by 18% as compared to non assisted µEDM. The best optimal combination of input parameters for improved performance measures were recorded as machining with ultrasonic vibration (U1), 0.25 kgf of magnetic pulling force (M1), 600 rpm of tool rotation (R2), 3.38 mJ of energy (E3) and 1.5 mm/min of Tool feed rate (F3). The confirmation trail was also carried out for the validation of the results attained by Grey Relational Analysis and confirmed that there is a substantial improvement with both assistance applied simultaneously.

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Srinivasan, Sriram, Lakshmikanthan Srivatsan, Rajaram Sathyanarayan, and B. Vijaya Ramnath. "MCDM Model for Selection of Optimum Machining Process." Materials Science Forum 773-774 (November 2013): 348–54. http://dx.doi.org/10.4028/www.scientific.net/msf.773-774.348.

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The work of manufacturing engineers is to utilize the minimum amount of energy or resources in bringing out a product without compromising on quality. Hence, to achieve this, the engineers must figure out the optimum or the best possible method to fabricate a product. This paper uses a multi criteria decision making (MCDM) model namely Analytical Hierarchical Process (AHP) to determine the best possible machining process to achieve the optimum results for an engraving operation on gear face in an automobile industry which uses five nontraditional machining processes viz; Laser Beam Machining (LBM), Ultrasonic Machining (USM), Electric Discharge Machining (EDM), Electrochemical Machining (ECM) and Electron Beam Machining (EBM). The five criteria considered in this paper are Material Removal Rate (MRR), Surface Finish, Depth Damage, Tolerance and Toxicity. The AHP result shows that ECM is the most suitable machining process as compared to others.

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Yu, Z. Y., K. P. Rajurkar, and A. Tandon. "Study of 3D Micro-Ultrasonic Machining." Journal of Manufacturing Science and Engineering 126, no. 4 (November 1, 2004): 727–32. http://dx.doi.org/10.1115/1.1813482.

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Many manufacturing processes, such as lithography, etching, laser, electrical discharge machining (EDM), and electrochemical machining (ECM), are being applied to produce the meso- and microscale parts and products. Materials such as silicon, glass, quartz crystal, and ceramics are being increasingly used in microelectromechanical system (MEMS) devices. Ultrasonic machining (USM) offers an attractive alternative to machine some of the hard and brittle materials. However, the tool wear in micro-ultrasonic machining adversely affects the machining accuracy. Therefore, it is necessary to account for and to compensate the tool wear during machining. This paper reports the feasibility of applying the uniform wear method developed for micro electrical discharge machining and its integration with CAD/CAM to microultrasonic vibration process for generating accurate three-dimensional (3D) microcavities. Experimental results show that the tool shape remains unchanged and the tool wear has been compensated.

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Zhong, Gao Yan, and Yan Qing Wang. "NC Ultrasonic Machining Efficiency: Neural Network-Based Modeling and Simulation." Advanced Materials Research 291-294 (July 2011): 406–10. http://dx.doi.org/10.4028/www.scientific.net/amr.291-294.406.

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To explore the impact of abrasive granularity, feed pressure and cutting feed speed on NC ultrasonic machining efficiency, a technological test was carried out, and based on the test results, back propagation (BP) neural network model was established and validated by simulation. The validation process showed that when relative error is less than ±10%, only two samples among 18 tested have larger errors. By the utilization of the BP network for training, correct fitting rate of machining efficiency target can be reached up to 88.9%. Our study indicates that (i) the output of the network is well fitted with the test data, (ii) the established model has good generalization ability to reflect the laws of NC ultrasonic machining process, and (iii) the model is suitable as a prediction tool for NC ultrasonic machining efficiency.

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Zhu, Yong Wei, Jian Shao, and Hong Zheng Chen. "Ultrasonic Modulating Compound Discharge – Electrochemical Micro-Fine Machining Technology and its Applications." Key Engineering Materials 609-610 (April 2014): 807–12. http://dx.doi.org/10.4028/www.scientific.net/kem.609-610.807.

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A new micro-fine manufacturing method is proposed, that is the ultrasonic modulating compound synchronous pulse electro-discharged and electrochemical machining. By the micro-fine machining way, the μm-level precision may be acquired. The low voltage, the low electric conductivitys working fluid mixed with the nm powders is used, as the ultrasonic vibration effect and the nm powders' catalyst effect between the electrodes, the micro-spark electro-discharged and the micro-electrolysis machining can be realized, the micro electro-discharged sparks can remove the electrolytic passivation film on the workpiece surface, ultrasonic vibrating blast wave can remove the machining outcomes and renew the working fluid, the better micro-fine machining precision can be acquired. Micro-fine compound machining system is build, the processing parameters can be adjusted online within a certain range, the synchronous pulses can be developed by the cutting circuit, the synchronization of frequency and phase can be ensured between the ultrasonic vibration and the electronic power, the precision and the process stability can be improved effectively. The mechanism tests are carried about the ultrasonic modulating compound discharge-electrochemical machining, a few of micro-structures are machined in μm-level machining precision, the fine machining mean's feasibility and technical superiority are verified too.

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Zheng, Shu You, and Xi Peng Xu. "Experimental Investigation on Ultrasonic Face Machining of Glass with Free Abrasives." Key Engineering Materials 375-376 (March 2008): 268–73. http://dx.doi.org/10.4028/www.scientific.net/kem.375-376.268.

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Serials of ultrasonic face machining experiments were designed and carried out on glass materials with free abrasives. Two different kinds of ultrasonic machining, namely, non-rotary ultrasonic machining (NRUSM) with free abrasives and rotary ultrasonic machining (RUSM) with free abrasives were compared. Two systems were set up to in-process monitor the changes of static forces and frequency respectively. The effects of static force, spindle speed and amplitude of ultrasonic vibration on material removal rate (MRR) and surface roughness were analyzed. The surface of workpieces was also observed by a digital video microscope system. The experimental results indicated that, at the given conditions, there exists an optimal value of static force and amplitude of vibration to obtain the maximum MRR, and RUSM was found to be superior to NRUSM in the MRR, but inversely in surface roughness.

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Lv, Zhe, Chuan Zhen Huang, Hong Tao Zhu, Jun Wang, Peng Yao, and Zeng Wen Liu. "An SPH Simulation on Vibration Assisted Abrasive Erosion of Hard Brittle Material in Abrasive Waterjet Machining." Advanced Materials Research 1017 (September 2014): 199–204. http://dx.doi.org/10.4028/www.scientific.net/amr.1017.199.

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Abrasive waterjet machining (AWJ) is one of the fastest growing non-conventional machining methods. However, low pressure and fine abrasive implemented in AWJ precision machining for reducing the surface damage reduce the efficiency. Therefore ultrasonic vibration is considered to apply on the workpiece to improve the machining efficiency. In order to analyze the effect of the vibration on erosion in AWJ machining, smoothed particle hydrodynamics (SPH) is used to simulate the erosion process for avoiding the mesh distortion in finite element method (FEM) when simulating large deformation and high strain rate problems. The results show that the application of ultrasonic vibration can effectively improve the erosion rate due to the dynamics variation of the erosion process.

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Wang, Jingsi, Shaolin Xu, Keita Shimada, Masayoshi Mizutani, and Tsunemoto Kuriyagawa. "Smoothed particle hydrodynamics simulation and experimental study of ultrasonic machining." Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture 232, no. 11 (February 20, 2017): 1875–84. http://dx.doi.org/10.1177/0954405417692005.

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Hard and brittle materials like glass and ceramics are highly demanded in modern manufacturing industries. However, their superior physical and mechanical properties lead to high cost of machining. Ultrasonic machining has been regarded as one of the most suitable fabrication techniques for these kinds of materials. A smoothed particle hydrodynamics model was proposed to study the material removal mechanism of the ultrasonic machining in this study. Influences of abrasive materials and the particle shapes on the crack formation of work substrates were investigated using this smoothed particle hydrodynamics model. Experiments were also conducted to verify the simulation model. Both of the simulation and experimental results show that using hard and spherical abrasive particles is helpful to improve the material removal efficiency. This work was the first to demonstrate the crack formation mechanisms during ultrasonic machining with different abrasive particles using smoothed particle hydrodynamics, which is significant for improving the machining performance of the ultrasonic machining process.

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Liu, En, Xiao Ping Hu, and Bao Hua Yu. "Research and Development of Ultrasonic CNC Cutting Path Generation System for Nomex Composite Materials." Advanced Materials Research 941-944 (June 2014): 1968–72. http://dx.doi.org/10.4028/www.scientific.net/amr.941-944.1968.

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There are a number of problems with the traditional way of machining Nomex composite materials, Ultrasonic vibration cutting as a new method can overcome most of the problems. This paper presents the machining process characteristics of ultrasonic cutting honeycomb structures of Nomex composite materials using two kinds of specials tools, and has a research on Ultrasonic machining tools posture control strategy, then proposed calculation method of generating the cutter location date. The main system was developed to meet the automatic generation cutting path of Nomex composite materials based on VS2008 and UG commercial software. The result of experiment shows this system can automatic generate rational machining path and correct NC date.

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YAMAGUCHI, Hitomi, and Takeo SHINMURA. "315 Study of micro-machining process with ultrasonic cavitation : Discussion of machining characteristics." Proceedings of The Manufacturing & Machine Tool Conference 2001.3 (2001): 95–96. http://dx.doi.org/10.1299/jsmemmt.2001.3.95.

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SHINMURA, Takeo, Hitomi YAMAGUCHI, Kenichirou KASAI, and Toshio AIZAWA. "416 Study on micro-machining process applying ultrasonic cavitation." Proceedings of Conference of Tohoku Branch 2000.35 (2000): 148–49. http://dx.doi.org/10.1299/jsmeth.2000.35.148.

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Singh, Rupinder. "Process capability study of ultrasonic machining for titanium alloys." International Journal of Materials Engineering Innovation 2, no. 3/4 (2011): 310. http://dx.doi.org/10.1504/ijmatei.2011.042884.

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Dong, Guo Jun, Ming Zhou, and Shao Nan Huang. "Study on the Surface Quality of Silicon Nitride Ceramics in Ultrasonic Vibration Grinding." Key Engineering Materials 579-580 (September 2013): 144–47. http://dx.doi.org/10.4028/www.scientific.net/kem.579-580.144.

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The conventional machining method for silicon nitride ceramics has low machining efficiency, prone to cracking, chipping and other defects. In this paper, the author carried out a study on the influence of ultrasonic vibration grinding on surface quality of silicon nitride ceramic, and carried out ultrasonic vibration grinding process test for silicon nitride ceramic and conducted the analysis of influence of this machining process on surface quality with orthogonal test. The test results showed that the influence on surface roughness decreased in the order of spindle speed, feed rate, cutting depth, and amplitude of vibration.

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Li, Li, Li Ling Qi, and Zong Wei Niu. "EDM with USM Combination Process of Sintered NdFeB Permanent Magnet." Applied Mechanics and Materials 44-47 (December 2010): 1066–69. http://dx.doi.org/10.4028/www.scientific.net/amm.44-47.1066.

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This paper presents an experimental investigation of the machining characteristics of sintered NdFeB permanent magnet using a combination process of electro-discharge machining (EDM) with ultrasonic machining (USM). Concentration of abrasive in the dielectric fluid is changed to explore its effect on the material removal rate (MRR). MRR of EDM /USM, conventional EDM are compared, machined surface characteristics are also compared between them. It is concluded that the combination EDM/USM process can increase the MRR and decrease the thickness of the recast layer. In the combination process, an appropriate abrasive concentration can improve its machining efficiency.

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Zou, Ping, Yingshuai Xu, Yu He, Mingfang Chen, and Hao Wu. "Experimental Investigation of Ultrasonic Vibration Assisted Turning of 304 Austenitic Stainless Steel." Shock and Vibration 2015 (2015): 1–19. http://dx.doi.org/10.1155/2015/817598.

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This research study focuses on the experimental analysis of the three-dimensional (3D) surface topography and surface roughness of the workpiece machined with ultrasonic vibration assisted turning (UAT) in comparison to conventional turning (CT). For the challenge that machining difficulties of 304 austenitic stainless steel (ASS 304) and high demands for the machined surface quality and machining precision represent, starting with cutting principle and processing technology, the ultrasonic vibration method is employed to scheme out a machining system of ultrasonic vibration assisted turning (MS-UAT). The experiments for turning the workpiece of ASS 304 are conducted with and without ultrasonic vibration using the designed MS-UAT, and then the 3D morphology evaluation parametersSaandSqare applied to characterize and analyse the machined surface. The experimental results obtained demonstrate that the process parameters in UAT of ASS 304 have obvious effect on the 3D surface topography and surface roughness of machined workpiece, and the appropriate choice of various process parameters, including ultrasonic amplitude, feed rate, depth of cut, and cutting speed, can enhance the machined surface quality efficiently to make the machining effect of UAT much better than that of CT.

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Tso, Pei Lum, Shi Guo Liu, and J. C. Wang. "The Development of an Ultrasonic Head for CMP Pad Conditioning." Advanced Materials Research 500 (April 2012): 275–80. http://dx.doi.org/10.4028/www.scientific.net/amr.500.275.

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The technology of ultrasonic assisted machining has been successfully used in many machining processes recently. Conditioning in the CMP not only can extending the life of the polishing pad but also improve process stability. In this paper we develop a brand new conditioning process with ultrasonic assisted conditioning UAC head for chemical mechanical polishing CMP process. The slurry came from inside the polishing spindle and had an independent cyclic system. As a result, this UAC device can remove polishing debris 4-6 times faster than conventional conditioning process. This conditioning process may even use water instead of slurry to reduce the cost of consumables of CMP. Key word: Chemical mechanical polishing CMP, Ultrasonic assisted conditioning UAC, Polishing Pad

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Chen, Tao, Shuliang Liu, Wu Liu, and Chaoqun Wu. "Study on a longitudinal–torsional ultrasonic vibration system with diagonal slits." Advances in Mechanical Engineering 9, no. 7 (July 2017): 168781401770634. http://dx.doi.org/10.1177/1687814017706341.

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The longitudinal–torsional ultrasonic vibration machining process is popular for machining hard and brittle materials. A longitudinal–torsional ultrasonic vibration system with diagonal slits was designed for the ultrasonic vibration machining process based on the principle of acoustics propagation in this study. Four uniform diagonal slits were cut off on the horn cylinder to transform the longitudinal ultrasonic vibration into a longitudinal–torsional composite motion. A finite element analysis was used to optimize the mechanical structure of the vibration system. Dynamic characteristics of the vibration system were numerically studied, and the relationship of diagonal slits versus the resonance frequency and amplitudes of longitudinal–torsional vibration was analyzed, so that the longitudinal–torsional output amplitude can be optimized by rational choice of structure parameters of diagonal slits. Moreover, the movement locus of the system output end was obtained by utilizing the Origin software, which was proved to be elliptical, and the accuracy of the finite element model was confirmed by comparing numerically and experimentally determined resonant characteristics. In addition, the verification of longitudinal–torsional ultrasonic vibration was proved for the designed ultrasonic vibration system.

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Kuai, Ji Cai. "Established and Experimental Study of ELID-Ultrasonic Honing System." Applied Mechanics and Materials 120 (October 2011): 381–84. http://dx.doi.org/10.4028/www.scientific.net/amm.120.381.

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The electrolytic in-process dressing (ELID) technology was combined with ultrasonic honing technology and ELID-ultrasonic honing system was proposed. And the electrolysis parameters, ultrasound parameters, honing parameters reasonable were matched for ELID- ultrasonic honing system and the honing processing experiments were carried out. Studies have shown that parameters in ELID-ultrasonic honing system are independent without disturbing each other. Compared to traditional honing and ultrasonic honing, ELID-ultrasonic honing system has a significant advantage in machining accuracy, surface roughness, processing efficiency and so on. The feasibility of ELID- ultrasonic honing system is validated, which provided a new compound method of honing for ultra-precision honing machining.

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Kong, Huanghai, Yong Liu, Xiangming Zhu, and Tengfei Peng. "Study on Ultrasonic Assisted Electrochemical Drill-Grinding of Superalloy." Chemosensors 8, no. 3 (August 3, 2020): 62. http://dx.doi.org/10.3390/chemosensors8030062.

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Electrochemical grinding (ECG) technique composed of electrochemical machining (ECM) and mechanical grinding is a proper method for machining of difficult-to-cut alloys. This paper presents a new ultrasonic assisted electrochemical drill-grinding (UAECDG) technique which combines electrochemical drilling, mechanical grinding, and ultrasonic vibration to fabricating high-quality small holes on superalloy. By applying ultrasonic vibration to high-speed rotating electrode in ECG, machining stability, efficiency, and surface quality can be obviously improved. Firstly, the electrochemical passive behavior of superalloy is studied, the mathematical model and simulation of gap electric field are established. Then, several experiments are conducted to investigate the influence of applied voltage, feed rate and ultrasonic amplitude on the machining quality. The balance of material removal between electrochemical reaction and mechanical grinding is achieved by optimizing the machining parameters. It reveals that the surface quality as well as machining stability and efficiency can be significantly improved by applying rotating ultrasonic vibration to the ECG process. Finally, several small holes of high quality have been machined successfully along with surface roughness of hole sidewall decreases from Ra 0.99 μm to Ra 0.14 μm by UAECDG.

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Journal articles on the topic 'Ultrasonic machining process'

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