Vibration-assisted machining (VAM) combines precision machining with small-amplitude tool vibration to improve the fabrication process. It has been applied to a number of processes from turning to drilling to grinding [9] , [36] . The emphasis on this literature review is the turning process where VAM has been applied to difficult applications such as diamond turning of ferrous and brittle materials, creating microstructures with complex geometries for products like molds and optical elements, or economically producing precision macro-scale components in hard alloys such as Inconel or titanium. This review paper presents the basic kinematic relationships for 1D (linear vibratory tool path) and 2D VAM (circular/elliptical tool path). Typical hardware systems used to achieve these vibratory motions are described. The periodic separation between the tool rake face and uncut material, characteristic of VAM, is related to observed reductions in machining forces and chip thickness, with distinct explanations offered for 1D and 2D modes. The reduced tool forces in turn are related to improvements in surface finish and extended tool life. Additional consideration is given to the intermittent cutting mechanism and how it reduces the effect of thermo-chemical mechanisms believed responsible for rapid wear of diamond tools when machining ferrous materials. The ability of VAM to machine brittle materials in the ductile regime at increased depth of cut is also described.

Review of vibration-assisted machining

Ultrasonically assisted turning of aviation materials

Ultrasonically assisted turning of aviation materials: simulations and experimental study.

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Ultrasonic cutting as a nonlinear (vibro-impact) process

Vibration excitation and energy transfer during ultrasonically assisted drilling

Autoresonant control of nonlinear mode in ultrasonic transducer for machining applications

Nonlinear models of the cutting process with superposition of ultrasonics are proposed and investigated. It is confirmed that under the influence of high frequency vibration, the phenomenological plasticisation of brittle materials and fluidisation of dry friction occurs. The mechanical characteristics of transformed machining processes are obtained. It is shown that excitation of the high-frequency nonlinear mode of tool— workpiece interaction is the most effective way of ultrasonically influencing the dynamic characteristics of machining. The exploitation of this mode needs a new method of nonlinear control, namely an autoresonant method. An autoresonant system with supervisory computer control has been developed and successfully used for the control of the piezoelectric transducer during ultrasonically assisted cutting.

Nonlinear Dynamics and Control of Ultrasonically Assisted Machining

This article provides a fundamental study into the trade-offs between the location of piezoceramic elements, resonant frequency, and achievable ultrasonic vibration amplitude at the working end of the bolted Langevin-style transducers (BLTs) for ultrasonically assisted machining (UAM) applications. Analytical models and finite-element (FE) models are established for theoretical study, which are then validated by experiments on four real electromechanical transducers. The results suggest that resonant frequency and oscillation amplitude of the BLTs depend essentially on the dimensions of the system and the location of the piezoceramic elements. The highest resonant frequency and the maximal vibration are achieved when the piezoceramic elements are at the longitudinal displacement node, where the highest effective electromechanical coupling coefficient value is exhibited. However, the minimal resonant frequency and the lowest vibration, which is almost equal to zero, are observed when the piezoceramic elements are located at the displacement antinode. In addition, the longitudinal displacement node locations are dependent on the resonant frequency of the devices rather than the locations of the piezoceramic elements.

/pdf/resonant-tuning-of-langevin-transducers-for-ultrasonically-1tltdtf5pp.pdf

Vladimir Astashev

Papers

Ultrasonic cutting as a nonlinear (vibro-impact) process

Vibration excitation and energy transfer during ultrasonically assisted drilling

Autoresonant control of nonlinear mode in ultrasonic transducer for machining applications

Nonlinear Dynamics and Control of Ultrasonically Assisted Machining

Resonant Tuning of Langevin Transducers for Ultrasonically Assisted Machining Applications