Experimental study on ultrasonic assisted milling effect on blade distortion

IF 17.7 1区化学 Q1 CHEMISTRY, MULTIDISCIPLINARY Accounts of Chemical Research Pub Date : 2024-03-26 DOI:10.1177/09544054241235736

Masuod Bayat, Saeid Amini

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Abstract

Distortion in milling is a prevalent issue that can arise during material machining. It stems from the forces exerted by the cutting tool on the machined material, resulting in uneven material removal and subsequent warping of the parts. The distortion can be prevented with proper cutting speed, feed rate, and tool selection. Ultrasonic-Assisted Milling (UAM) mitigates distortion in milling processes by optimizing cutting conditions. This machining technique employs high-frequency vibrations to efficiently remove material from a workpiece. In this study, 18 tests according to a full factorial design experiment were used to investigate cutting force and distortion in two modes of conventional milling and ultrasonic-assisted milling. Our findings reveal a direct correlation between cutting force and distortion in UAM. Specifically, UAM exhibited a significant reduction of approximately 28.4% in cutting force compared to conventional milling (CM). Furthermore, distortion in UAM was diminished by about 34.06%. Additionally, a noteworthy improvement of 28.4% in surface roughness was observed. These results collectively help produce accurate workpieces and ensure the production of undamaged and warp-free parts.

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超声波辅助铣削对刀片变形影响的实验研究

铣削变形是材料加工过程中普遍存在的问题。它源于切削工具对加工材料施加的力，导致材料去除不均匀，进而使零件变形。适当的切削速度、进给量和刀具选择可以防止变形。超声波辅助铣削（UAM）通过优化切削条件来减轻铣削过程中的变形。这种加工技术利用高频振动来有效去除工件上的材料。本研究采用全因子设计实验法进行了 18 次测试，以研究传统铣削和超声波辅助铣削两种模式下的切削力和变形。我们的研究结果表明，在 UAM 中，切削力和变形之间存在直接关联。具体而言，与传统铣削（CM）相比，UAM 的切削力显著降低了约 28.4%。此外，UAM 的变形减少了约 34.06%。此外，表面粗糙度也显著提高了 28.4%。这些结果共同帮助生产出精确的工件，并确保生产出无损坏、无翘曲的零件。

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来源期刊

Accounts of Chemical Research 化学-化学综合

CiteScore

31.40

自引率

1.10%

发文量

312

审稿时长

2 months

期刊介绍： Accounts of Chemical Research presents short, concise and critical articles offering easy-to-read overviews of basic research and applications in all areas of chemistry and biochemistry. These short reviews focus on research from the author’s own laboratory and are designed to teach the reader about a research project. In addition, Accounts of Chemical Research publishes commentaries that give an informed opinion on a current research problem. Special Issues online are devoted to a single topic of unusual activity and significance. Accounts of Chemical Research replaces the traditional article abstract with an article "Conspectus." These entries synopsize the research affording the reader a closer look at the content and significance of an article. Through this provision of a more detailed description of the article contents, the Conspectus enhances the article's discoverability by search engines and the exposure for the research.