TY - GEN
T1 - A Study of Influence Factors on Form Error and Surface Finish in the High-frequency Ultrasonic Vibration-assisted Cutting of Structured Surfaces
AU - Zhang, Canbin
AU - Cheung, Chi Fai
AU - Bulla, Benjamin
N1 - The authors would like to express their sincere thanks to the Innovation and Technology Commission (ITC) of the Government of the Hong Kong Special Administrative Region (HKSAR) for the financial support of the research work under the project (Projec code: GHP/142/19SZ) and the Research and Innovation Office (Project code: RK2Z) from The Hong Kong Polytechnic University. Special thanks are also due to the contract research project between the State Key Laboratory of
Ultra-precision Machining Technology of The Hong Kong Polytechnic University and Son-X, Gmbh, Aachen, Germany.
PY - 2022/6/3
Y1 - 2022/6/3
N2 - Ultrasonic vibration-assisted cutting (UVAC) is able to improve material machinability. For an ultrasonic tooling system, vibration amplitude is a key factor to be controlled which has significant effect on tool trajectory, cutting ratio, lubrication condition, etc. It plays an important role in affecting the form error of the workpiece being machined. In this paper, the high-frequency ultrasonic vibration-assisted cutting (HFUVAC) system, UTS2 with a frequency of 104 kHz is used to study influence factors including vibration amplitude, slope angle of the target profile and workpiece material on form error and surface finish of the structured surface. The input current which is in proportion to vibration amplitude is set as 20, 30 and 40 mA with an amplitude of about 0.5 - 1.0 μm, to machine cosine structures with various maximum slope angles on easy-to-machine material (copper alloy) and hard-to-machine material (steel), respectively. An analytical and experimental investigation has been conducted. The results show that slope angle of the target profile and workpiece material have a larger effect on form error than vibration amplitude. In HFUVAC of hard-to-machine materials with a higher hardness, form error increases significantly with increasing slope angle of the target profile, due to less cut of material caused by indentation effect in the downhill profile.
AB - Ultrasonic vibration-assisted cutting (UVAC) is able to improve material machinability. For an ultrasonic tooling system, vibration amplitude is a key factor to be controlled which has significant effect on tool trajectory, cutting ratio, lubrication condition, etc. It plays an important role in affecting the form error of the workpiece being machined. In this paper, the high-frequency ultrasonic vibration-assisted cutting (HFUVAC) system, UTS2 with a frequency of 104 kHz is used to study influence factors including vibration amplitude, slope angle of the target profile and workpiece material on form error and surface finish of the structured surface. The input current which is in proportion to vibration amplitude is set as 20, 30 and 40 mA with an amplitude of about 0.5 - 1.0 μm, to machine cosine structures with various maximum slope angles on easy-to-machine material (copper alloy) and hard-to-machine material (steel), respectively. An analytical and experimental investigation has been conducted. The results show that slope angle of the target profile and workpiece material have a larger effect on form error than vibration amplitude. In HFUVAC of hard-to-machine materials with a higher hardness, form error increases significantly with increasing slope angle of the target profile, due to less cut of material caused by indentation effect in the downhill profile.
KW - high-frequency
KW - ultrasonic vibration-assisted cutting
KW - vibration amplitude
KW - form error
KW - structured surface
KW - ulra-precision machining
M3 - Conference article published in proceeding or book
SP - ecopy
BT - Proceedings of the 22nd International Conference of the European Society for Precision Engineering and Nanotechnology
PB - euspen
ER -