The first book to comprehensively address the theory, kinematic modelling, numerical simulation and applications of vibration assisted machining
Vibration Assisted Machining: Theory, Modelling and Applications covers all key aspects of vibration assisted machining, including cutting kinematics and dynamics, the effect of workpiece materials and wear of cutting tools. It also addresses practical applications for these techniques. Case studies provide detailed guidance on the design, modeling and testing of VAM systems. Experimental machining methods are also included, alongside considerations of state-of-the-art research developments on cutting force modeling and surface texture generation.
Advances in computational modelling, surface metrology and manufacturing science over the past few decades have led to tremendous benefits for industry. This is the first comprehensive book dedicated to design, modelling, simulation and integration of vibration assisted machining system and processes, enabling wider industrial application of the technology. This book enables engineering students and professionals in manufacturing to understand and implement the latest vibration assisted machining techniques. Highlights include:
- Comprehensive coverage of the theory, kinematics modelling, numerical simulation and applications of vibration assisted machining (VAM)
- Case studies with detailed guidance on design, modelling and testing of VAM systems, as well as experimental machining methods
- Discussion of state-of-the-art research developments on cutting force modelling and surface texture generation
- Coverage of the history of VAM, its current applications and future directions for the technology
Vibration Assisted Machining: Theory, Modelling and Applications provides engineering students, researchers, manufacturing engineers, production supervisors, tooling engineers, planning and application engineers and machine tool designers with the fundamentals of vibration assisted machining, along with methodologies for developing and implementing the technology to solve practical industry problems.
Table of Contents
Preface xi
1 Introduction to Vibration-Assisted Machining Technology 1
1.1 Overview of Vibration-Assisted Machining Technology 1
1.1.1 Background 1
1.1.2 History and Development of Vibration-Assisted Machining 2
1.2 Vibration-Assisted Machining Process 3
1.2.1 Vibration-Assisted Milling 3
1.2.2 Vibration-Assisted Drilling 3
1.2.3 Vibration-Assisted Turning 5
1.2.4 Vibration-Assisted Grinding 5
1.2.5 Vibration-Assisted Polishing 6
1.2.6 Other Vibration-Assisted Machining Processes 7
1.3 Applications and Benefits of Vibration-Assisted Machining 7
1.3.1 Ductile Mode Cutting of Brittle Materials 7
1.3.2 Cutting Force Reduction 8
1.3.3 Burr Suppression 8
1.3.4 Tool Life Extension 8
1.3.5 Machining Accuracy and Surface Quality Improvement 9
1.3.6 Surface Texture Generation 10
1.4 Future Trend of Vibration-Assisted Machining 10
References 12
2 Review of Vibration Systems 17
2.1 Introduction 17
2.2 Actuators 18
2.2.1 Piezoelectric Actuators 18
2.2.2 Magnetostrictive Actuators 18
2.3 Transmission Mechanisms 18
2.4 Drive and Control 19
2.5 Vibration-Assisted Machining Systems 19
2.5.1 Resonant Vibration Systems 19
2.5.1.1 1D System 20
2.5.1.2 2D and 3D Systems 23
2.5.2 Nonresonant Vibration System 27
2.5.2.1 2D System 29
2.5.2.2 3D Systems 34
2.6 Future Perspectives 35
2.7 Concluding Remarks 36
References 37
3 Vibration System Design and Implementation 45
3.1 Introduction 45
3.2 Resonant Vibration System Design 46
3.2.1 Composition of the Resonance System and Its Working Principle 46
3.2.2 Summary of Design Steps 46
3.2.3 Power Calculation 47
3.2.3.1 Analysis of Working Length Lpu 48
3.2.3.2 Analysis of Cutting Tool Pulse Force Fp 49
3.2.3.3 Calculation of Total Required Power 49
3.2.4 Ultrasonic Transducer Design 49
3.2.4.1 Piezoelectric Ceramic Selection 49
3.2.4.2 Calculation of Back Cover Size 51
3.2.4.3 Variable Cross-Sectional, One-Dimensional Longitudinal Vibration Wave Equation 51
3.2.4.4 Calculation of Size of Longitudinal Vibration Transducer Structure 53
3.2.5 Horn Design 53
3.2.6 Design Optimization 54
3.3 Nonresonant Vibration System Design 55
3.3.1 Modeling of Compliant Mechanism 56
3.3.2 Compliance Modeling of Flexure Hinges Based on the Matrix Method 56
3.3.3 Compliance Modeling of Flexure Mechanism 59
3.3.4 Compliance Modeling of the 2 DOF Vibration Stage 61
3.3.5 Dynamic Analysis of the Vibration Stage 62
3.3.6 Finite Element Analysis of the Mechanism 63
3.3.6.1 Structural Optimization 63
3.3.6.2 Static and Dynamic Performance Analysis 63
3.3.7 Piezoelectric Actuator Selection 65
3.3.8 Control System Design 66
3.3.8.1 Control Program Construction 66
3.3.9 Hardware Selection 66
3.3.10 Layout of the Control System 68
3.4 Concluding Remarks 68
References 69
3.A Appendix 70
4 Kinematics Analysis of Vibration-Assisted Machining 73
4.1 Introduction 73
4.2 Kinematics of Vibration-Assisted Turning 74
4.2.1 TWS in 1D VAM Turning 75
4.2.2 TWS in 2D VAM Turning 78
4.3 Kinematics of Vibration-Assisted Milling 80
4.3.1 Types of TWS in VAMilling 81
4.3.1.1 Type I 81
4.3.1.2 Type II 82
4.3.1.3 Type III 82
4.3.2 Requirements of TWS 83
4.3.2.1 Type I Separation Requirements 83
4.3.2.2 Type II Separation Requirements 85
4.3.2.3 Type III Separation Requirements 87
4.4 Finite Element Simulation of Vibration-Assisted Milling 89
4.5 Conclusion 93
References 93
5 Tool Wear and Burr Formation Analysis in Vibration-Assisted Machining 95
5.1 Introduction 95
5.2 Tool Wear 95
5.2.1 Classification of Tool Wear 95
5.2.2 Wear Mechanism and Influencing Factors 96
5.2.3 Tool Wear Reduction in Vibration-Assisted Machining 98
5.2.3.1 Mechanical Wear Suppression in 1D Vibration-Assisted Machining 98
5.2.3.2 Mechanical Wear Suppression in 2D Vibration-Assisted Machining 101
5.2.3.3 Thermochemical Wear Suppression in Vibration-Assisted Machining 102
5.2.3.4 Tool Wear Suppression in Vibration-Assisted Micromachining 106
5.2.3.5 Effect of Vibration Parameters on Tool Wear 107
5.3 Burr Formation 108
5.4 Burr Formation and Classification 109
5.5 Burr Reduction in Vibration Assisted Machining 109
5.5.1 Burr Reduction in Vibration-Assisted Micromachining 111
5.6 Concluding Remarks 113
5.6.1 Tool Wear 113
5.6.2 Burr Formation 115
References 115
6 Modeling of Cutting Force in Vibration-Assisted Machining 119
6.1 Introduction 119
6.2 Elliptical Vibration Cutting 120
6.2.1 Elliptical Tool Path Dimensions 120
6.2.2 Analysis and Modeling of EVC Process 120
6.2.2.1 Analysis and Modeling of Tool Motion 120
6.2.2.2 Modeling of Chip Geometric Feature 120
6.2.2.3 Modeling of Transient Cutting Force 124
6.2.3 Validation of the Proposed Method 126
6.3 Vibration-Assisted Milling 127
6.3.1 Tool-Workpiece Separation in Vibration Assisted Milling 128
6.3.2 Verification of Tool-Workpiece Separation 131
6.3.3 Cutting Force Modeling of VAMILL 133
6.3.3.1 Instantaneous Uncut Thickness Model 133
6.3.3.2 Cutting Force Modeling of VAMILL 136
6.3.4 Discussion of Simulation Results and Experiments 137
6.4 Concluding Remarks 143
References 143
7 Finite Element Modeling and Analysis of Vibration-Assisted Machining 145
7.1 Introduction 145
7.2 Size Effect Mechanism in Vibration-Assisted Micro-milling 147
7.2.1 FE Model Setup 148
7.2.2 Simulation Study on Size Effect in Vibration-Assisted Machining 151
7.3 Materials Removal Mechanism in Vibration-Assisted Machining 152
7.3.1 Shear Angle 152
7.3.2 Simulation Study on Chip Formation in Vibration-Assisted Machining 154
7.3.3 Characteristics of Simulated Cutting Force and von-Mises Stress in Vibration-Assisted Micro-milling 156
7.4 Burr Control in Vibration-Assisted Milling 158
7.4.1 Kinematics Analysis 159
7.4.2 Finite Element Simulation 160
7.5 Verification of Simulation Models 161
7.5.1 Tool Wear and Chip Formation 162
7.5.2 Burr Formation 163
7.6 Concluding Remarks 164
References 164
8 Surface Topography Simulation Technology for Vibration-Assisted Machining 167
8.1 Introduction 167
8.2 Surface Generation Modeling in Vibration-Assisted Milling 171
8.2.1 Cutter Edge Modeling 172
8.2.2 Kinematics Analysis of Vibration-Assisted Milling 173
8.2.3 Homogeneous Matrix Transformation 174
8.2.3.1 Basic Theory of HMT 174
8.2.3.2 Establishment of HTM in the End Milling Process 174
8.2.3.3 HMT in VAMILL 176
8.2.4 Surface Generation 185
8.2.4.1 Surface Generation Simulation 185
8.3 Vibration-Assisted Milling Experiments 187
8.4 Discussion and Analysis 187
8.4.1 The Influence of the Vibration Parameters on the Surface Wettability 188
8.4.2 Tool Wear Analysis 189
8.5 Concluding Remarks 189
References 189
Index 193
