High-frequency vibration effects on material removal mechanisms in ultrasonic transverse scratching of carbon fiber reinforced plastics.

This paper represented some fundamental investigations on the potential effects of the high-frequency vibration on material removal mechanisms in ultrasonic transverse scratching of carbon fiber reinforced plastics (CFRPs). It was found that the ultrasonic superimposition brought about the evident reduction of the ductile-brittle transition depth of the unidirectional CFRPs. For the scratched groove generated without ultrasonic, the tensile stress and compressive stress caused by the indenter penetration were respectively responsible for the formations of the radial cracks at the leading edges and the central region. Under the combination of the inertia effects induced by the ultrasonic superposition and the skin-core structure of the carbon fibers, the micro-defects situated at the interior of the fibers were nucleated simultaneously, and their propagations caused the formations of the oblique cracks. Incorporated with the strain rate effects of the materials, a fresh theoretical model was proposed to describe the evolution of the mechanical stress during the scratching process. The fiber fragments induced by the oblique cracks were just concentrated on the top surface of the scratched groove, due to the coupling effects of the small penetration depth of the indenter and the express reduction of strain rate.

High-frequency vibration effects on the hole integrity in rotary ultrasonic drilling of carbon fiber-reinforced plastic composites.

This investigation represented a fundamental research on the potential effects of the high-frequency vibration on the hole integrity involved in rotary ultrasonic drilling (RUD) of carbon fiber-reinforced plastic (CFRP) composites. It was found the increased thickness of the CFRP plate shrunk the flowing velocity of the coolant, which brought about the residual chippings gradually accumulated at the radial clearance between the tool and the material. Furthermore, the chipping accumulation at the clearance seriously increased the friction effects and the resultant thermal load, thus leading to the chipping adhesions on the tool surface and machined cylinder jamming at the central hole of the tool. The mutual constrain between two vertical bundles brought the delamination around the holes generated in conventional drilling (CD) process to a termination at the bundle interface. The ultrasonic superimposition reduced the thrust force of the diamond tool which provided inadequate energy for the delaminated fibers reaching the bundle interface. Moreover, hole position on the two-dimensional orthogonal fabrics significantly influenced the propagation of the delaminated fibers, which weakened the effects of the drilling parameters on the delamination dimensions. Additionally, superimposing an ultrasonic vibration prolonged the abrasive trajectories and increased their overlapping probability, and the induced smoothing effects resulted in the obvious reduction of the surface roughness. The tensile stress exerted on the margin of the machined surface was responsible for the initiation of the CD delamination. After the delaminated fibers reached the bundle interface, the further extrusion of tool brought about the margin suffered from the shear stress, thus leading to the collapse of the machined cylinder. Considering the thrust force of the diamond tool and the undrilled thickness of the machined surface, the critical conditions of the delamination initiation were developed, which revealing that the decreasing of the thrust force caused the reduction of the critical undrilled thickness.

Mechanistic prediction for cutting force in rotary ultrasonic machining of BK7 glass based on probability statistics.

Material removal in rotary ultrasonic machining (RUM) of hard-brittle material is an abnormal complicated process, which involves the combination effects of the numerous abrasive grains with the random distributions in the dimensions and penetration depths. These stochastic characteristics result in the evident differences in the extrusion loading between the material and each individual grain, and their aggregate effects serve to significantly affect the cutting force of the diamond tool. However, few mechanistic prediction models of the cutting force have incorporated in the random distribution features of the abrasive grains, restricting the current optimization methods for the reduction of the cutting force during the formal RUM process. Giving consideration to the abrasive processing kinematics and their distribution features on the tool end-face, the number of the effective grains together with their penetration depths was calculated utilizing the probability statistics. Subsequently, the novel theoretical model of the cutting force was established by incorporating the gaussian distribution characteristics of the grain size and their penetration depths. Afterward, the confirmatory experiments were performed for the validation of the proposed cutting force model, revealing that the predicted results were accordant well with the experimental measurements. Furthermore, it was found that the number of the active abrasive grains accounted for 2.972% of the total number on the tool end-face at the specific processing parameters. Additionally, the mechanistic predictions of the developed model represented that the cutting force depicting an irregular decreasing trend with the grain dimension increasing, which was attributed to the coupling effects between the grain size and their number.

High-frequency vibration effects on hole entrance chipping in rotary ultrasonic drilling of BK7 glass.

This present investigation exhibited some fundamental information about the influence of the high-frequency vibration on the hole entrance chipping formation involved in rotary ultrasonic drilling (RUD) of BK7 glass process. The entrance chipping morphologies, produced with and without ultrasonic, were observed and evaluated with respect to the fracture mechanics of brittle material. Giving consideration to the variation characteristics of the plastic deformation region in the interior material induced by the specific kinematics principles of the abrasive, the ultrasonic effects on the chipping formation mechanisms were investigated by assessing the groove morphologies obtained in the scratching experiment utilizing the formation mechanisms of the lateral cracking. Furthermore, the formal confirmatory tests with and without ultrasonic were performed to validate these chipping formation mechanisms. It was found that the plastic deformed region reached its maximum at the trajectory bottom. Moreover, the propagation of the lateral cracking initially nucleated at the bottom of the ductile deformation zone resulted in the formation of the entrance chipping in formal RUD process. The slight deformation of the material at the two terminals of each groove produced with ultrasonic would provide the inhibitory effects to the further extending of the lateral cracks, which would shrink with the increased spindle speed, and the inhibitory effect dominated in determining the improvement effects on the hole entrance quality. Additionally, a theoretical relationship between the nucleation depth and the propagation length of the lateral cracking was developed for the conventional drilling (CD) process.