Freeform surface fabrication on hardened steel by double frequency vibration cutting

Yanjie Yuan*, Dawei Zhang, Xiubing Jing, Kornel Ehmann

*Corresponding author for this work

Research output: Contribution to journalArticle

Abstract

Hardened steel is a typical hard-to-cut material and is widely used in mechanical components and molds. It is still challenging to precisely and efficiently fabricate freeform surfaces on hardened steel using conventional slow slide servo (SSS) and fast tool servo (FTS) diamond turning. Ever since the double frequency vibration cutting method has been proposed, its advantages have been demonstrated in machining microstructures on steels. Nevertheless, the surface quality and the depth of the machined microstructures by this method remains limited due to limitations imposed by existing double frequency vibration cutting systems. Therefore, an improved double frequency vibration cutting process and the corresponding cutting system were developed. The system consists of a 1D non-resonant compliant vibrator, a 2D resonant ultrasonic vibrator, a three-axis translational stage and a control system. In this system, the low frequency vibration generated by the 1D non-resonant compliant vibrator is used to generate the freeform surface, while the ultrasonic elliptical vibrations generated by the 2D resonant ultrasonic vibrator are responsible for improving the machinability of the hard-to-cut material. In addition, benefiting from the newly proposed configuration, the developed double frequency vibration cutting system overcomes some inherent drawbacks of the conventional SSS/FTS. Based on the working principle of this double frequency vibration cutting method, a tool vibration path generation strategy is proposed. To ascertain the feasibility of the developed double frequency vibration cutting system, experiments were conducted on hardened steel. The machined freeform surfaces show high consistency with the simulation results.

Original languageEnglish (US)
Article number116369
JournalJournal of Materials Processing Technology
Volume275
DOIs
StatePublished - Jan 1 2020

Fingerprint

Steel
Vibrators
Fabrication
Ultrasonics
Vibrations (mechanical)
Microstructure
Diamond
Machinability
Molds
Surface properties
Diamonds
Machining
Control systems

Keywords

  • Compliant machining
  • Double frequency vibration cutting
  • Elliptical vibration cutting
  • Freeform surface
  • Hard-to-cut material machining

ASJC Scopus subject areas

  • Ceramics and Composites
  • Computer Science Applications
  • Metals and Alloys
  • Industrial and Manufacturing Engineering

Cite this

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title = "Freeform surface fabrication on hardened steel by double frequency vibration cutting",
abstract = "Hardened steel is a typical hard-to-cut material and is widely used in mechanical components and molds. It is still challenging to precisely and efficiently fabricate freeform surfaces on hardened steel using conventional slow slide servo (SSS) and fast tool servo (FTS) diamond turning. Ever since the double frequency vibration cutting method has been proposed, its advantages have been demonstrated in machining microstructures on steels. Nevertheless, the surface quality and the depth of the machined microstructures by this method remains limited due to limitations imposed by existing double frequency vibration cutting systems. Therefore, an improved double frequency vibration cutting process and the corresponding cutting system were developed. The system consists of a 1D non-resonant compliant vibrator, a 2D resonant ultrasonic vibrator, a three-axis translational stage and a control system. In this system, the low frequency vibration generated by the 1D non-resonant compliant vibrator is used to generate the freeform surface, while the ultrasonic elliptical vibrations generated by the 2D resonant ultrasonic vibrator are responsible for improving the machinability of the hard-to-cut material. In addition, benefiting from the newly proposed configuration, the developed double frequency vibration cutting system overcomes some inherent drawbacks of the conventional SSS/FTS. Based on the working principle of this double frequency vibration cutting method, a tool vibration path generation strategy is proposed. To ascertain the feasibility of the developed double frequency vibration cutting system, experiments were conducted on hardened steel. The machined freeform surfaces show high consistency with the simulation results.",
keywords = "Compliant machining, Double frequency vibration cutting, Elliptical vibration cutting, Freeform surface, Hard-to-cut material machining",
author = "Yanjie Yuan and Dawei Zhang and Xiubing Jing and Kornel Ehmann",
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Freeform surface fabrication on hardened steel by double frequency vibration cutting. / Yuan, Yanjie; Zhang, Dawei; Jing, Xiubing; Ehmann, Kornel.

In: Journal of Materials Processing Technology, Vol. 275, 116369, 01.01.2020.

Research output: Contribution to journalArticle

TY - JOUR

T1 - Freeform surface fabrication on hardened steel by double frequency vibration cutting

AU - Yuan, Yanjie

AU - Zhang, Dawei

AU - Jing, Xiubing

AU - Ehmann, Kornel

PY - 2020/1/1

Y1 - 2020/1/1

N2 - Hardened steel is a typical hard-to-cut material and is widely used in mechanical components and molds. It is still challenging to precisely and efficiently fabricate freeform surfaces on hardened steel using conventional slow slide servo (SSS) and fast tool servo (FTS) diamond turning. Ever since the double frequency vibration cutting method has been proposed, its advantages have been demonstrated in machining microstructures on steels. Nevertheless, the surface quality and the depth of the machined microstructures by this method remains limited due to limitations imposed by existing double frequency vibration cutting systems. Therefore, an improved double frequency vibration cutting process and the corresponding cutting system were developed. The system consists of a 1D non-resonant compliant vibrator, a 2D resonant ultrasonic vibrator, a three-axis translational stage and a control system. In this system, the low frequency vibration generated by the 1D non-resonant compliant vibrator is used to generate the freeform surface, while the ultrasonic elliptical vibrations generated by the 2D resonant ultrasonic vibrator are responsible for improving the machinability of the hard-to-cut material. In addition, benefiting from the newly proposed configuration, the developed double frequency vibration cutting system overcomes some inherent drawbacks of the conventional SSS/FTS. Based on the working principle of this double frequency vibration cutting method, a tool vibration path generation strategy is proposed. To ascertain the feasibility of the developed double frequency vibration cutting system, experiments were conducted on hardened steel. The machined freeform surfaces show high consistency with the simulation results.

AB - Hardened steel is a typical hard-to-cut material and is widely used in mechanical components and molds. It is still challenging to precisely and efficiently fabricate freeform surfaces on hardened steel using conventional slow slide servo (SSS) and fast tool servo (FTS) diamond turning. Ever since the double frequency vibration cutting method has been proposed, its advantages have been demonstrated in machining microstructures on steels. Nevertheless, the surface quality and the depth of the machined microstructures by this method remains limited due to limitations imposed by existing double frequency vibration cutting systems. Therefore, an improved double frequency vibration cutting process and the corresponding cutting system were developed. The system consists of a 1D non-resonant compliant vibrator, a 2D resonant ultrasonic vibrator, a three-axis translational stage and a control system. In this system, the low frequency vibration generated by the 1D non-resonant compliant vibrator is used to generate the freeform surface, while the ultrasonic elliptical vibrations generated by the 2D resonant ultrasonic vibrator are responsible for improving the machinability of the hard-to-cut material. In addition, benefiting from the newly proposed configuration, the developed double frequency vibration cutting system overcomes some inherent drawbacks of the conventional SSS/FTS. Based on the working principle of this double frequency vibration cutting method, a tool vibration path generation strategy is proposed. To ascertain the feasibility of the developed double frequency vibration cutting system, experiments were conducted on hardened steel. The machined freeform surfaces show high consistency with the simulation results.

KW - Compliant machining

KW - Double frequency vibration cutting

KW - Elliptical vibration cutting

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