An analytical model of rotary ultrasonic milling

Erich Bertsche*, Kornel Ehmann, Kostyantyn Malukhin

*Corresponding author for this work

Research output: Contribution to journalArticlepeer-review

45 Scopus citations

Abstract

Rotary ultrasonic machining is currently being used as a manufacturing method for advanced ceramic materials, but its complexity has hindered its acceptance in industry. For this technology to gain wider acceptance, it must first be scientifically better understood. The majority of published rotary ultrasonic machining (RUM) papers studied the effect of RUM process parameters on machining performance and removal mechanisms for drilling of circular holes. In industries such as aerospace, the production of advanced turbine components requires machining of complex 3D features using milling strategies. The objective of this paper will be to present a new physical model based on rotary ultrasonic milling which will help provide a better scientific understanding of the process. This will be accomplished by first modeling the macro kinematics between the tool and material followed by the modeling of micro kinematics between the individual diamond grains and the material. In addition, a force model for predicting machining process forces will also be introduced and validated based on a set of experiments. The physical models will help determine the relationships between input parameters, cutting parameters, and process output parameters for rotary ultrasonic milling.

Original languageEnglish (US)
Pages (from-to)1705-1720
Number of pages16
JournalInternational Journal of Advanced Manufacturing Technology
Volume65
Issue number9-12
DOIs
StatePublished - Jan 1 2013

Keywords

  • Advanced ceramics
  • Experimental verification
  • Rotary ultrasonic milling
  • Surface finish
  • Theoretical cutting forces

ASJC Scopus subject areas

  • Control and Systems Engineering
  • Software
  • Mechanical Engineering
  • Computer Science Applications
  • Industrial and Manufacturing Engineering

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