Daxi Geng

Bio: Daxi Geng is an academic researcher from Beihang University. The author has contributed to research in topics: Machining & Surface integrity. The author has an hindex of 11, co-authored 24 publications receiving 577 citations.

Delamination formation and suppression during rotary ultrasonic elliptical machining of CFRP

Abstract: As a superior hole manufacturing process, rotary ultrasonic elliptical machining (RUEM) has been successfully employed for drilling carbon fiber reinforced plastics (CFRPs) recently. The delamination of CFRP during drilling is generally considered as the most undesirable form of damage and the most challenging failure mode. In order to reduce the delamination in this novel process, it is important to understand the formation and suppression mechanisms during RUEM of CFRP. In this study, the delamination formation in both core drilling (CD) and RUEM was observed and analyzed. The variation trend of delamination factor with feed speed as well as cutting speed was obtained. The experimental results show that, compared with CD, RUEM method can effectively reduce hole exit delamination by 5.4%–19.3% between 1/2 plies and 0.7%–8.4% between 2/3 plies at the feed rates from 50 to 100 μm/rev. Moreover, the delamination suppression mechanism in RUEM was fully analyzed and verified. In a word, in the industry practice, RUEM can be considered as a competitive and promising technique to drill CFRP compared to other delamination suppression techniques.

Cutting temperature and resulting influence on machining performance in rotary ultrasonic elliptical machining of thick CFRP

Abstract: As a novel non-conventional machining process, rotary ultrasonic elliptical machining (RUEM) has been successfully used for drilling thick carbon fiber-reinforced plastics (CFRPs) recently. In order to reduce the thermal damage, the measurement of cutting temperature is important when RUEM of CFRP. In this research, the cutting temperatures in both RUEM and grinding drilling (GD) were measured by an infrared camera under dry condition. Temperature trends as functions of feed rate and cutting speed were obtained and the results showed that compared to GD, RUEM can effectively reduce the maximum temperature by 18.8% and 13.1% at the feed rate of 75 and 150 μm/rev respectively. Both mechanisms of temperature reduction and chip adhesion prevention in RUEM were analyzed. In addition, SEM observation of the machined surface revealed that better microstructure was obtained in RUEM compared to GD under the same cutting condition.

Study on rotary ultrasonic-assisted drilling of titanium alloys (Ti6Al4V) using 8-facet drill under no cooling condition

Abstract: Titanium alloys (Ti6Al4V) have been widely applied in modern aerospace industry as structural components due to their excellent mechanical and physical properties. Meanwhile, the drilling process is essential for machining the assembly holes of Ti6Al4V. However, Ti6Al4V is also a difficult-to-cut material owing to their low thermal conductivity and high chemical reactivity with many tool materials during machining, which easily lead to rapid tool wear, premature tool failure, and poor machining quality. This has attracted wide attention of researchers. In recent years, the rotary ultrasonic-assisted drilling (RUAD) technology, as a novel machining method, has been found to be very effective in the machining of difficult-to-cut materials like nickel alloys and titanium alloys. This paper first introduced an 8-facet drill tool and combined the advantages of RUAD to carry out a study on the drilling of Ti6Al4V under no cooling condition. The experimental results indicated that compared with the common drilling (CD) of Ti6Al4V, in RUAD process with the vibration amplitude of 10 μm, the thrust force, torque, cutting temperature near the drilled hole exit, surface roughness of drilled hole, expansion increment of hole diameter, and burr height of drilled hole exit decreased by 16.79 to 20.2 %, 31.5 to 33.6 %, 18.54 to 21.68 %, 24.87 to 25.36 %, 46.75 to 57.63 %, and 82.27 to 89.18 %, respectively; the excellent chip breakability and removal effect of chip evacuation, superior surface integrity of drilled hole, enhanced tool cutting ability, and prolonged tool life were obtained in RUAD. Furthermore, the experimental results also proved that the drilling technology of RUAD of Ti6Al4V using the 8-facet drill was feasible and the cutting effects were superior.

Review of ultrasonic vibration-assisted machining in advanced materials

Abstract: Compared to conventional machining (CM), ultrasonic vibration-assisted machining (UVAM) with high-frequency and small-amplitude has exhibited good cutting performances for advanced materials. In recent years, advances in ultrasonic generator, ultrasonic transducer, and horn structures have led to the rapid progress in the development of UVAM. Following this trend, numerous new design requirements and theoretical concepts have been proposed and studied successively, however, very few studies have been conducted from a comprehensive perspective. To address this gap in the literature and understanding the development trend of UVAM, a critical overview of UVAM is presented in this study, covering different vibration-assisted machining styles, device architectures, and theoretical analysis. This overview covers the evolution of typical hardware systems used to achieve vibratory motions from the one-dimensional UVAM to three-dimensional UVAM, the discussion of cutting characteristics with periodic separation between the tools and workpiece and the analysis of processing properties. Challenges for UVAM include ultrasonic vibration systems with high power, large amplitude, and high efficiency, as well as theoretical research on the dynamics and cutting characteristics of UVAM. Consequently, based on the current limitations and challenges, device improvement and theoretical breakthrough play a significant role in future research on UVAM.

Advanced cutting tools and technologies for drilling carbon fibre reinforced polymer (CFRP) composites: A review

Abstract: Carbon fibre reinforced polymer (CFRP) composites have excellent specific mechanical properties, these materials are therefore widely used in high-tech industries like the automobile and aerospace sectors. The mechanical machining of CFRP composites is often necessary to meet dimensional or assembly-related requirements; however, the machining of these materials is difficult. In an attempt to explore this issue, the main objective of the present paper is to review those advanced cutting tools and technologies that are used for drilling carbon fibre reinforced polymer composites. In this context, this paper gives a detailed review and discussion of the following: (i) the machinability of CFRP including chip removal mechanisms, cutting force, tool wear, surface roughness, delamination and the characteristics of uncut fibres; (ii) cutting tool requirements for CFRP machining; and (iii) recent industrial solutions: advanced edge geometries of cutting tools, coatings and technologies. In conclusion, it can be stated that advanced geometry cutting tools are often necessary in order to effectively and appropriately machine required quality features when working with CFRP composites.