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Journal articles on the topic 'Ultrasonically-assisted turning'

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Author: Grafiati

Published: 10 December 2022

Last updated: 28 January 2023

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1

Ahmed, N., A. V. Mitrofanov, Vladimir I. Babitsky, and Vadim V. Silberschmidt. "Stresses in Ultrasonically Assisted Turning." Applied Mechanics and Materials 5-6 (October 2006): 351–58. http://dx.doi.org/10.4028/www.scientific.net/amm.5-6.351.

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Ultrasonically assisted turning (UAT) is a novel material-processing technology, where high frequency vibration (frequency f ≈ 20kHz, amplitude a ≈15μm) is superimposed on the movement of the cutting tool. Advantages of UAT have been demonstrated for a broad spectrum of applications. Compared to conventional turning (CT), this technique allows significant improvements in processing intractable materials, such as high-strength aerospace alloys, composites and ceramics. Superimposed ultrasonic vibration yields a noticeable decrease in cutting forces, as well as a superior surface finish. A vibro-impact interaction between the tool and workpiece in UAT in the process of continuous chip formation leads to a dynamically changing stress distribution in the process zone as compared to the quasistatic one in CT. The paper presents a three-dimensional, fully thermomechanically coupled computational model of UAT incorporating a non-linear elasto-plastic material model with strain-rate sensitivity and contact interaction with friction at the chip–tool interface. 3D stress distributions in the cutting region are analysed for a representative cycle of ultrasonic vibration. The dependence of various process parameters, such as shear stresses and cutting forces on vibration frequency and amplitude is also studied.

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2

Farahnakian, Masoud, Mohamad Ebrahim Keshavarz, Sadegh Elhami, and Mohammad Reza Razfar. "Effect of cutting edge modification on the tool flank wear in ultrasonically assisted turning of hardened steel." Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture 233, no. 5 (April 4, 2016): 1472–82. http://dx.doi.org/10.1177/0954405416640416.

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Ultrasonically assisted turning is one of the modern machining processes developed in recent decades to facilitate machining of hard-to-cut materials which are widely used in different industries. Cutting tool wear is one of the main problems in machining of hard materials which has necessitated implementation of modern machining processes such as ultrasonically assisted turning. Due to vibro-impact conditions, cutting tool failure takes place when ultrasonically assisted turning is applied for hard and brittle materials. In fact, microchipping takes place in the tool nose after machining of short length, so sharp cutting edge fails at the early stages of cutting. Therefore, if the sharpness of cutting edge is removed before the machining, the fracture of cutting edge, caused by vibro-impact condition, will be eliminated. The aim of this research is to investigate the tungsten carbide tool flank wear in ultrasonically assisted turning of hardened alloy steel in comparison to the conventional turning. Therefore, a proper experimental ultrasonic vibration configuration was designed to apply the ultrasonic vibrations to the turning tool along cutting direction. Experiments were carried out for different cutting speeds below the critical speed in ultrasonically assisted turning. Application of the tool with modified specifications led to make an initial wear on tool flank, but finally a significant improvement of tool wear was observed.

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3

Hara, Keisuke, Daisuke Hashikai, Hiromi Isobe, Jun Ishimatsu, Yoshihiro Take, and Toshihiko Koiwa. "Investigation of Cutting Phenomena in High Speed Ultrasonic Turning." Key Engineering Materials 523-524 (November 2012): 209–14. http://dx.doi.org/10.4028/www.scientific.net/kem.523-524.209.

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This study investigated phenomena of ultrasonic cutting in case of high speed conditions. Ultrasonically assisted cutting techniques were developed by Kumabe in 1950’s. He found “critical cutting speed” that limits cutting speed to obtain ultrasonically assisted effects and is calculated by frequency and amplitude of oscillation. In general, ultrasonically assisted cutting is not suitable for high speed cutting conditions because the effects of ultrasonically applying are canceled due to tool contacts with workpiece during cutting operation. Present ultrasonically assisted cutting cannot increase cutting speed because cutting speed is limited by above reason. And ultrasonically assisted cutting cannot improve productivity due to long processing time. We conducted high speed ultrasonic cutting, maximum cutting speed of this research was 160m/min which is higher than general critical cutting speed. Workpiece material is JIS SUS304 stainless steed and cemented carbide tool inserts were employed in this research. In ordinary cutting, generate terrible built up edge on to tool rake face. In case of low amplitude ultrasonic cutting, tool rake face hasn’t built up edge and periodically marks by ultrasonic oscillation were remained on the surface. Cutting phenomena of ultrasonic cutting is different compared with ordinary cutting conditions.

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4

Babitsky, V. I., A. N. Kalashnikov, A. Meadows, and A. A. H. P. Wijesundara. "Ultrasonically assisted turning of aviation materials." Journal of Materials Processing Technology 132, no. 1-3 (January 2003): 157–67. http://dx.doi.org/10.1016/s0924-0136(02)00844-0.

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5

Muhammad, Riaz, Agostino Maurotto, Anish Roy, and Vadim V. Silberschmidt. "Analysis of Forces in Vibro-Impact and Hot Vibro-Impact Turning of Advanced Alloys." Applied Mechanics and Materials 70 (August 2011): 315–20. http://dx.doi.org/10.4028/www.scientific.net/amm.70.315.

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Analysis of the cutting process in machining of advanced alloys, which are typically difficult-to-machine materials, is a challenge that needs to be addressed. In a machining operation, cutting forces causes severe deformations in the proximity of the cutting edge, producing high stresses, strain, strain-rates and temperatures in the workpiece that ultimately affect the quality of the machined surface. In the present work, cutting forces generated in a vibro-impact and hot vibro-impact machining process of Ti-based alloy, using an in-house Ultrasonically Assisted Turning (UAT) setup, are studied. A three-dimensional, thermo-mechanically coupled, finite element model was developed to study the thermal and mechanical processes in the cutting zone for the various machining processes. Several advantages of ultrasonically assisted turning and hot ultrasonically assisted turning are demonstrated when compared to conventional turning.

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6

Volkov, G. A., V. A. Bratov, A. A. Gruzdkov, V. I. Babitsky, Y. V. Petrov, and V. V. Silberschmidt. "Energy-Based Analysis of Ultrasonically Assisted Turning." Shock and Vibration 18, no. 1-2 (2011): 333–41. http://dx.doi.org/10.1155/2011/598106.

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The process of ultrasonically-assisted turning (UAT) is a superposition of vibration of a cutting tool on its standard movement in conventional turning (CT). The former technique has several advantages compared with the latter, one of the main being a significant decrease in the level of cutting forces. In this paper the effects observed in UAT are analysed employing ideas of dynamic fracture mechanics. The active stage of loading duration depends heavily on ultrasonic frequency and the cutting speed; he application of the fracture criterion based on the notion of incubation time makes it possible to calculate a dependence of this duration on its threshold amplitude. An estimation of energy, necessary to create a threshold pulse in the material, is made by solving the contact Hertz problem. The obtained time dependence of energy has a marked minimum. Thus, the existence of energy-efficient loading duration is demonstrated. This explains the decrease in the cutting force resulting from superimposed ultrasonic vibration. The obtained results are in agreement with experiments on ultrasonic assisted machining of aluminium and Inconel 718 alloy.

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7

Silberschmidt, Vadim V., Sameh M. A. Mahdy, Moustafa A. Gouda, Ahmed Naseer, Agostino Maurotto, and Anish Roy. "Surface-roughness Improvement in Ultrasonically Assisted Turning." Procedia CIRP 13 (2014): 49–54. http://dx.doi.org/10.1016/j.procir.2014.04.009.

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8

Ahmed, N., A. V. Mitrofanov, V. I. Babitsky, and V. V. Silberschmidt. "Analysis of forces in ultrasonically assisted turning." Journal of Sound and Vibration 308, no. 3-5 (December 2007): 845–54. http://dx.doi.org/10.1016/j.jsv.2007.04.003.

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9

Mitrofanov, A. V., V. I. Babitsky, and V. V. Silberschmidt. "Finite element simulations of ultrasonically assisted turning." Computational Materials Science 28, no. 3-4 (November 2003): 645–53. http://dx.doi.org/10.1016/j.commatsci.2003.08.020.

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10

Muhammad, Riaz, Naseer Ahmed, Murat Demiral, Anish Roy, and Vadim V. Silberschmidt. "Computational Study of Ultrasonically-Assisted Turning of Ti Alloys." Advanced Materials Research 223 (April 2011): 30–36. http://dx.doi.org/10.4028/www.scientific.net/amr.223.30.

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Industrial applications of titanium alloys especially in aerospace, marine and offshore industries have grown significantly over the years primarily due to their high strength, light weight as well as good fatigue and corrosion-resistance properties. The machinability of these difficult-to-cut metallic materials with conventional turning (CT) techniques has seen a limited improvement over the years. Ultrasonically-assisted turnning (UAT) is an advanced machining process, which has shown to have specific advantages, especially in the machining of high-strength alloys. In this study a three-dimensional finite element model of ultrasonically-assisted oblique cutting of a Ti-based super-alloy is developed. The nonlinear temperature-sensitive material behaviour is incorporated in our numerical simulations based on results obtained with split-Hopkinson pressure bar tests. Various contact conditions are considered at the tool tip-workpiece interface to get an in-depth understanding of the mechanism influencing cutting parameters. The simulation results obtained are compared for both CT and UAT conditions to elucidate main deformation mechanisms responsible for the observed changes in the material’s responses to cutting techniques.

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11

Ahmed, Naseer, Alexander V. Mitrofanov, Vladimir I. Babitsky, and Vadim Silberschmidt. "Enhanced finite element model of ultrasonically assisted turning." International Journal of Machining and Machinability of Materials 6, no. 1/2 (2009): 159. http://dx.doi.org/10.1504/ijmmm.2009.026934.

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12

Muhammad, Riaz, Agostino Maurotto, Anish Roy, and Vadim V. Silberschmidt. "Hot Ultrasonically Assisted Turning of β-Ti Alloy." Procedia CIRP 1 (2012): 336–41. http://dx.doi.org/10.1016/j.procir.2012.04.060.

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13

Mitrofanov, A. V., V. I. Babitsky, and V. V. Silberschmidt. "Thermomechanical finite element simulations of ultrasonically assisted turning." Computational Materials Science 32, no. 3-4 (March 2005): 463–71. http://dx.doi.org/10.1016/j.commatsci.2004.09.019.

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14

Ahmed, N., A. V. Mitrofanov, V. I. Babitsky, and V. V. Silberschmidt. "3D finite element analysis of ultrasonically assisted turning." Computational Materials Science 39, no. 1 (March 2007): 149–54. http://dx.doi.org/10.1016/j.commatsci.2005.12.045.

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15

Muhammad, R., A. Maurotto, A. Roy, and V. V. Silberschmidt. "Ultrasonically assisted turning of Ti-6Al-2Sn-4Zr-6Mo." Journal of Physics: Conference Series 382 (August 22, 2012): 012016. http://dx.doi.org/10.1088/1742-6596/382/1/012016.

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16

Maurotto, Agostino, Riaz Muhammad, Anish Roy, and Vadim V. Silberschmidt. "Enhanced ultrasonically assisted turning of a β-titanium alloy." Ultrasonics 53, no. 7 (September 2013): 1242–50. http://dx.doi.org/10.1016/j.ultras.2013.03.006.

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17

Khajehzadeh, Mohsen, and Mohammad Reza Razfar. "Theoretical modeling of tool mean temperature during ultrasonically assisted turning." Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture 230, no. 4 (December 2, 2014): 675–93. http://dx.doi.org/10.1177/0954405414556333.

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18

Babitsky, V. I., A. V. Mitrofanov, and V. V. Silberschmidt. "Ultrasonically assisted turning of aviation materials: simulations and experimental study." Ultrasonics 42, no. 1-9 (April 2004): 81–86. http://dx.doi.org/10.1016/j.ultras.2004.02.001.

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19

Mitrofanov, A. V., V. I. Babitsky, and V. V. Silberschmidt. "Finite element analysis of ultrasonically assisted turning of Inconel 718." Journal of Materials Processing Technology 153-154 (November 2004): 233–39. http://dx.doi.org/10.1016/j.jmatprotec.2004.04.299.

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20

Mahdy, S. M. A., M. A. Gouda, and V. V. Silberschmidt. "Study of ultrasonically assisted turning of stainless steel and brass alloys." Journal of Physics: Conference Series 451 (July 17, 2013): 012037. http://dx.doi.org/10.1088/1742-6596/451/1/012037.

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21

Li, Zhanjie, Gang Jin, Fengzhou Fang, Hu Gong, and Haili Jia. "Ultrasonically Assisted Single Point Diamond Turning of Optical Mold of Tungsten Carbide." Micromachines 9, no. 2 (February 12, 2018): 77. http://dx.doi.org/10.3390/mi9020077.

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22

Muhammad, Riaz, Naseer Ahmed, Himayat Ullah, Anish Roy, and Vadim V. Silberschmidt. "Hybrid machining process: experimental and numerical analysis of hot ultrasonically assisted turning." International Journal of Advanced Manufacturing Technology 97, no. 5-8 (May 8, 2018): 2173–92. http://dx.doi.org/10.1007/s00170-018-2087-6.

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23

Khajehzadeh, Mohsen, Mohammad Reza Razfar, and Mehdi Akhlaghi. "Experimental Investigation of Tool Temperature During Ultrasonically Assisted Turning of Aerospace Aluminum." Materials and Manufacturing Processes 29, no. 11-12 (October 7, 2014): 1453–60. http://dx.doi.org/10.1080/10426914.2014.930962.

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24

Sharma, Varun, Pulak M. Pandey, Uday S. Dixit, Anish Roy, and Vadim V. Silberschmidt. "Finite element simulations of conventional and ultrasonically assisted turning processes with plane and textured cutting inserts." Journal of Micromanufacturing 3, no. 1 (November 10, 2019): 54–68. http://dx.doi.org/10.1177/2516598419878022.

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This paper investigates the performance of conventional turning and ultrasonically assisted turning (UAT) processes with plane and textured cutting inserts. Simulations based on the finite-element method were carried out using a software package ABAQUS/Explicit (Dassault Systemes, France). The obtained results were validated experimentally by employing a specially developed UAT setup. The purpose of the paper is to analyze cutting-force variation by the use of textured cutting inserts. Optimized dimensions of the texture pattern were used to model textured cutting inserts. The cutting-force variation in UAT was assessed with finite-element method, confirming diminishing cutting forces at a tool–workpiece interface during a noncontact time. The use of the textured cutting inserts in the UAT process resulted in the lowest cutting forces when compared to a plane tool in UAT as well as both plane and textured tools in the conventional turning process.

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25

Mitrofanov, A. V., N. Ahmed, V. I. Babitsky, and V. V. Silberschmidt. "Effect of lubrication and cutting parameters on ultrasonically assisted turning of Inconel 718." Journal of Materials Processing Technology 162-163 (May 2005): 649–54. http://dx.doi.org/10.1016/j.jmatprotec.2005.02.170.

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26

Muhammad, Riaz, Naseer Ahmed, Anish Roy, and Vadim V. Silberschmidt. "Turning of Advanced Alloys with Vibrating Cutting Tool." Solid State Phenomena 188 (May 2012): 277–84. http://dx.doi.org/10.4028/www.scientific.net/ssp.188.277.

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A demand for high-strength alloys in aerospace, marine and off-shore industries has stimulated development of new and efficient machining techniques. In the recent past, a novel machining technique known as ultrasonically assisted turning (UAT) has been introduced; in it low-energy ultrasonic vibration is superimposed on movement of a cutting tool. In the present work, a comparative study of machining of two advanced alloys - Ti15V3Cr3Al3Sn and Inconel 718 - is carried out numerically by developing a two-dimensional finite-element model of the turning process. A non-linear material description is used in the FE model to incorporate plastic deformation behaviour of the high-strength alloys. The model is employed to investigate the effect of tool geometry and contact conditions on cutting forces, temperature of the cutting region and the chip shape in orthogonal turning of modern alloys.

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27

Muhammad, Riaz, Mohammad Sajid Hussain, Agostino Maurotto, Carsten Siemers, Anish Roy, and Vadim V. Silberschmidt. "Analysis of a free machining α+β titanium alloy using conventional and ultrasonically assisted turning." Journal of Materials Processing Technology 214, no. 4 (April 2014): 906–15. http://dx.doi.org/10.1016/j.jmatprotec.2013.12.002.

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28

Muhammad, R., A. Mistry, S. W. Khan, N. Ahmed, A. Roy, and V. V. Silberschmidt. "Analysis of tool wear in ultrasonically assisted turning of -Ti-15V-3Al-3Cr-3Sn alloy." Scientia Iranica 23, no. 4 (October 1, 2016): 1800–1810. http://dx.doi.org/10.24200/sci.2016.3927.

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29

Maurotto, Agostino, Anish Roy, Vladimir I. Babitsky, and Vadim V. Silberschmidt. "Analysis of Machinability of Ti- and Ni-Based Alloys." Solid State Phenomena 188 (May 2012): 330–38. http://dx.doi.org/10.4028/www.scientific.net/ssp.188.330.

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Efficient machining of advanced Ti- and Ni-based alloys, which are typically difficult-to-machine, is a challenge that needs to be addressed by the industry. During a typical machining operation of such alloys, high cutting forces imposed by a tool on the work-piece material lead to severe deformations in the process zone, along with high stresses, strains and temperatures in the material, eventually affecting the quality of finished work-piece. Conventional machining (CT) of Ti- and Ni-based alloys is typically characterized by low depths of cuts and relatively low feed rates, thus adversely affecting the material removal rates (MRR) in the machining process. In the present work, a novel machining technique, known as Ultrasonically Assisted Turning (UAT) is shown to dramatically improve machining of these intractable alloys. The developed machining process is capable of high MRR with an improved surface quality of the turned work-piece. Average cutting forces are significantly lower in UAT when compared to those in traditional turning techniques at the same machining parameters, demonstrating the capability of vibration-assisted machining as a viable machining method for the future.

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30

Shi, Q., Y. Y. Tse, R. Muhammad, A. Roy, V. V. Silberschmidt, and R. L. Higginson. "Effect of Machining on Shear-Zone Microstructure in Ti-15V-3Cr-3Al-3Sn: Conventional and Ultrasonically Assisted Turning." Journal of Materials Engineering and Performance 25, no. 9 (July 21, 2016): 3766–73. http://dx.doi.org/10.1007/s11665-016-2209-y.

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31

Khajehzadeh, M., M. Akhlaghi, and M. R. Razfar. "Finite element simulation and experimental investigation of tool temperature during ultrasonically assisted turning of aerospace aluminum using multicoated carbide inserts." International Journal of Advanced Manufacturing Technology 75, no. 5-8 (August 14, 2014): 1163–75. http://dx.doi.org/10.1007/s00170-014-6163-2.

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32

Wu, Yong Bo, Jing Ti Niu, M. Fujimoto, and Mitsuyoshi Nomura. "Fundamental Machining Characteristics of Ultrasonic Assisted Turning of Titanium Alloy Ti-6Al-4V." Advanced Materials Research 797 (September 2013): 344–49. http://dx.doi.org/10.4028/www.scientific.net/amr.797.344.

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In this paper, a new machining method is proposed for the high efficiency turning of titanium alloy Ti-6Al-4V in which the cutting tool is ultrasonically vibrated. An experimental setup is constructed by installing an ultrasonic cutting unit onto a NC lathe followed by experimental investigations on the fundamental machining characteristics. The results obtained in the current work showed that (1) the cutting force decreases with the increase in the power supplying level (i.e., the ultrasonic vibration (UV) amplitude), e.g., the cutting force components in X-. Y-and Z-directions were decreased by 48%, 45% and 87%, respectively, once the UV has been applied to the tool at the power supplying level of 50%; (2) the cutting marks with knit pattern are formed on work-surface with UV while the parallel distributed cutting marks are generated without UV, and the surface roughness is decreased by up to 10% when the UV is applied at an appropriate power supplying level; (3) the work-surface straightness is improved by 46% once the UV is applied.

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33

Patwari, Anayet U., Mohammad Ahsan Habib, Md S. I. Chowdhury, Afzal H. Neelav, Md Sharfat Latif, and T. M. M. Sunny. "IMPROVEMENT OF SURFACE ROUGHNESS DURING TURNING OF PRE-HEATED MILD STEEL USING VOICE ACTIVATED ULTRASONIC WAVES." Jurnal Teknologi 76, no. 6 (September 29, 2015). http://dx.doi.org/10.11113/jt.v76.5698.

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Surface roughness represents the dimensional accuracy of the finished product and is one of the most important quality parameters of the finished product. For improvement of the surface quality several techniques like magnetic field, ultrasonic assisted turning and so on has been introduced. Ultrasonically Assisted Turning has been one of the techniques which showed great promise. It is a hybrid technique based on superimposition of ultrasonic vibration on a movement of a cutting tool in turning process. In this paper, a new technique using the concept of voice activated mode generated ultrasonic smart waves has been proposed and adopted with an aim to improve average surface roughness of the preheated machined surface of mild steel. Externally voice activated ultrasonic sound waves were applied during turning process of preheated mild steel and its effect on average surface roughness was studied. Experimentations were carried out under different ultrasonic frequencies to determine the surface roughness to the best degree possible. The experimental results showed significant improvements in surface roughness in preheated machined products.

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34

Muhammad, Riaz, Naseer Ahmed, Himayat Ullah, and Vadim V. Silberschmidt. "Dynamic Behaviour of β-Ti-15333 in Ultrasonically Assisted Turning: Experimental and Numerical Analysis." Scientia Iranica, August 29, 2017, 0. http://dx.doi.org/10.24200/sci.2017.4312.

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