Development of a Novel 2-D Vibration-Assisted Compliant Cutting System for Surface Texturing

Wu Le Zhu*, Zhiwei Zhu, Yu He, Kornel F. Ehmann, Bing Feng Ju, Shizhen Li

*Corresponding author for this work

Research output: Contribution to journalArticlepeer-review

37 Scopus citations

Abstract

This paper presents a novel two-dimensional vibration-assisted compliant cutting system (2-D VCCS) to be used on conventional machines for generating textured surfaces with uniform and accurate topography. The proposed system is specifically designed to be capable of delivering high-amplitude vibrations with decoupled guidance at the tool tip, while keeping high resistance to cutting forces during the texturing process. The matrix-based compliance modeling method is adopted for compliance and dynamic modeling of the 2-D VCCS. With optimized structural parameters, the model is validated by theoretical and finite element analysis. On-machine performance tests were conducted to identify the vibration amplitudes, stiffness, and frequency responses of the device. Finally, various complex textured surfaces were uniformly and accurately generated by the high-performance 2-D VCCS using a V-shaped diamond tool. The actually textured surfaces were evaluated and shown that they closely match the theoretically predicted surfaces based on the in-process monitored parameters, demonstrating the great potential of the 2-D VCCS to create functional surfaces for industrial products.

Original languageEnglish (US)
Article number7898796
Pages (from-to)1796-1806
Number of pages11
JournalIEEE/ASME Transactions on Mechatronics
Volume22
Issue number4
DOIs
StatePublished - Aug 2017

Keywords

  • Compliant manufacturing systems
  • high amplitude/stiffness
  • surface texturing
  • vibration-assisted cutting

ASJC Scopus subject areas

  • Control and Systems Engineering
  • Computer Science Applications
  • Electrical and Electronic Engineering

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