Vibration Assisted Machining - Theory, Modelling and Applications

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.

List 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

About the author

Dr. Lu Zheng received his MSc and PhD in Mechanical Engineering from Newcastle University, UK in 2016 and 2020, respectively. He is currently a Lecturer at China Agricultural University. His research interests include cutting performance and functional surface generation in vibration assisted machining.
Dr. Wanqun Chen received his PhD in mechanical engineering from Harbin Institute of Technology, China in 2014. Currently, he is an Associate Professor at Harbin Institute of Technology. His research interests include ultra-precision machining and vibration assisted machining. He has published more than 80 peer reviewed papers, contributed to three book chapters and holds six patents. Dr. Dehong Huo is currently a Senior Lecturer in Precision Engineering at the School of Engineering, Newcastle University, UK. Currently, his work in precision manufacturing is focused on precision/micro machining processes for hard-to-machine materials and hybrid manufacturing processes. He is the co-author of four books and more than 100 papers in international journals and conferences. He is the editor and reviewer of many international journals and is an organizer for several international scientific conferences.

Product details

• Authors: Wanqun Chen, Dehong Huo, Huo Dehong, Lu Zheng, Lu (Newcastle University Zheng, Zheng Lu
• Publisher: Wiley, John and Sons Ltd
• Languages: English
• Product format: Hardback
• Released: 18.03.2021
• EAN: 9781119506355
• ISBN: 978-1-119-50635-5
• No. of pages: 208
• Series: Wiley-ASME Press Series
• Subjects: Natural sciences, medicine, IT, technology > Physics, astronomy > Mechanics, acoustics; Maschinenbau, Materialverarbeitung, Materialwissenschaften, Industrial Engineering, Mechanical Engineering, Solid Mechanics, Materials science, Festkörpermechanik, Industrielle Verfahrenstechnik, Produktion i. d. Industriellen Verfahrenstechnik, Industrial Engineering / Manufacturing, Materials Processing