Commenced in January 2007
Paper Count: 31105
Prediction of Tool and Nozzle Flow Behavior in Ultrasonic Machining Process
Authors: Vinod Kumar, Jatinder Kumar
Abstract:The use of hard and brittle material has become increasingly more extensive in recent years. Therefore processing of these materials for the parts fabrication has become a challenging problem. However, it is time-consuming to machine the hard brittle materials with the traditional metal-cutting technique that uses abrasive wheels. In addition, the tool would suffer excessive wear as well. However, if ultrasonic energy is applied to the machining process and coupled with the use of hard abrasive grits, hard and brittle materials can be effectively machined. Ultrasonic machining process is mostly used for the brittle materials. The present research work has developed models using finite element approach to predict the mechanical stresses sand strains produced in the tool during ultrasonic machining process. Also the flow behavior of abrasive slurry coming out of the nozzle has been studied for simulation using ANSYS CFX module. The different abrasives of different grit sizes have been used for the experimentation work.
Digital Object Identifier (DOI): doi.org/10.5281/zenodo.1332994Procedia APA BibTeX Chicago EndNote Harvard JSON MLA RIS XML ISO 690 PDF Downloads 2517
 G. J.P. Choi, B.H. Jeon, B.H. Kim, "Chemical-assisted ultrasonic machining of glass," International journal of Machine Tools & Manufacture, 44,703-723, 2002.
 M. Xiao a,, K. Sato a, S. Karube a, T. Soutome, "The effect of tool nose radius in ultrasonic vibration cutting of hard metal" International journal of Machine Tools & Manufacture 43, 1375-1382,2003
 Gilmore, R., ÔÇÿÔÇÿUltrasonic Machining and Polishing,-- Proc. Int. Symposium for Electro machining, Lausanne, Switzerland, pp. 941-95, 1995.
 Ya G, Qin HW, Yang SG, Xu YW, "Analysis of the rotary machining mechanism", J Mater Process Technology 129:182-185,2002.
 Thoe TB, Aspinwall DK, Wise MLH, "Review of ultrasonic machining", Int J Mach Tool Manufacturing 38(4):239-255, 1998.
 Gilmore R, "Ultrasonic machining: a case study," J Mater Process Technology 28:139-148, 1991.
 Z. Y. Yu, K. P. Rajurkar, A. Tandon, "Study of 3D Micro-Ultrasonic Machining," Journal of Manufacturing Science and Engineering Vol. 126, 2004.
 Yu, Z. Y., Masuzawa, T., and Fujino, M., ÔÇÿÔÇÿ3D Micro-EDM With Simple Shaped", 1998.
 Yu, Z. Y., Masuzawa, T., and Fujino, M., ÔÇÿÔÇÿMicro-EDM for Three Dimensional Cavities,ÔÇöDevelopment of Uniform Wear Method,-- CIRP Ann, 47:1, pp. 169-172, 1998..
 Rajurkar, K. P., and Yu, Z. Y., ÔÇÿÔÇÿ3D Micro-EDM Using CAD/CAM,-- CIRP Ann., 49, pp. 127-130, 2000.
 D.Prabhakar, "Machining advanced ceramic materials using rotary ultrasonic machining process," M.S. Thesis, University of Illinois at Urbana-Champaign,. Pp.167-172, 1992.
 Z.J. Pei, N. Khanna, P.M. Ferreira, "An investigation into rotary ultrasonic machining of structural ceramics: a review," Ceramic Engineering and Science Proceedings 16 (1) 259-278, 1995.
 Z.C. Li, Liang-wu Cai, Z.J. Pei, C. Treadwell, "Finite element simulation of rotary ultrasonic machining for advanced ceramics," Proceedings of ASME International Mechanical Engineering Congress and Exposition, Anaheim, CA, USA, November13-19,2004.
 Hara, K., Kyusojin, A., Isobe, H., Yanagi, K. and Yoshihara, H. "Study on mirror surface grinding of die steel by using ultrasonically assisted diamond tool," Trans. of Int. Conf. on Leading Edge Manufacturing in the 21st Century, pp. 631-634,2005.
 Y.Q. Cao, "Failure analysis of exit edges in ceramic machining using finite element analysis", Engineering Failure Analysis 8 (4) 325-338, 2001
 W.C. Chiu, M.D. Thouless, W.J. Endres , "An analysis of chipping in brittle materials," International Journal of Fracture 90 (4) 287-298, 1998.
 Q.H. Zhang, J.H. Zhang, Z.X. Jia, X. Ai, "Fracture at the exit of the hole during the ultrasonic drilling of engineering ceramics," Journal of Material Processing Technology 84 20-24,1998.
 ANSYS Advanced analysis procedure manual, ANSYS 5.4, ANSYS Inc., Canonsburg, Pennsylvania c SAS IP, Inc.
 Shuvra Das, Mathias Klotz, F. Klocke, "EDM simulation: Finite element-based calculation of deformation," microstructure and residual stresses, Journal of Materials Processing Technology 142 434-451, 2003.
 V. Yadav, V.K. Jain, P.M. Dixit, "Thermal stresses due to electrical discharge machining," International Journal of Machine Tools and Manufacturing 42 877-88,2002.