Development of a 3D Vibration Assisted Machining System

3D 振动辅助加工系统的开发

• 批准号: EP/M020657/1
• 负责人: Dehong Huo
• 金额: $ 38.01万
• 依托单位: Newcastle University
• 依托单位国家: 英国
• 项目类别: Research Grant
• 财政年份: 2015
• 资助国家: 英国
• 起止时间: 2015 至 无数据
• 项目状态: 已结题
• 来源: https://gtr.ukri.org/projects?ref=EP%2FM020657%2F1
• 关键词: Development; 3D; Vibration; Assisted; Machining

Vibrations between the workpiece and the cutting tools in machining processes can deteriorate machining accuracy and surface quality. However controlled small amplitude (several microns) high frequency (tens of kHz) vibrations can facilitate machining processes. This is called vibration assisted machining (VAM). VAM combines precision machining with small amplitude vibration between tool and workpiece, and for appropriate machining and vibration parameter sets, the tool can periodically loses contact with the chip, which changes the cutting kinematics and mechanics, and can improve machining performance. Reported benefits include: reductions in machining forces; improved surface finish and form accuracy; suppression of burr formation; reduction of tool wear and extension of tool life; etc. In turning process, the vibration assistance is relatively easy to implement as the tool is stationary. Both 1D vibration assisted system, i.e. linear vibration assistance in the cutting direction, and 2D vibration assisted system, i.e. elliptical vibration motion in the plane of cutting direction and depth of cut direction have been applied in turning processes with success. Due to the complexity of kinematics and dynamics of the milling process, application of vibration assistance to milling has received little attention. Currently efforts on vibration assisted milling are purely empirical and lack accurate kinematic and dynamic models to design an optimal VAM system, and all 2D vibration assisted milling studies have been limited to low frequencies which are not applicable to micro milling operations. In addition, to obtain complex shape geometry, the milling process requires a feed vector in arbitrary direction in space, i.e. both a vertical and horizontal components of feed vector are necessary for 3D end milling. However, currently no 3D VAM systems have been reported. To overcome these limitations on the state-of-the-art and make use of the advantages of vibration assistance, this project will develop a novel compact 3D vibration assisted machining system for micro milling of free-form surfaces on hard-to-machine materials, and evaluate its performance through machining experiments. Fabrication of precision micro products from hard-to-machine materials, such as semiconductor materials, piezoelectric materials, glasses, is increasingly in demand in various applications such as bio-engineering, MEMS, optics, etc. Success of the project would open new industrial avenues for processing such materials at a more cost-effective manner. However, to achieve this in practice, development of a 3D vibration assisted machining system and its associated design and modelling methodology are urgently needed.

加工过程中工件和切削刀具之间的振动会降低加工精度和表面质量。然而，受控的小振幅（几微米）高频（数十kHz）振动可以促进加工过程。这称为振动辅助加工 (VAM)。 VAM将精密加工与刀具和工件之间的小振幅振动相结合，对于适当的加工和振动参数设置，刀具可以周期性地失去与切屑的接触，从而改变切削运动学和力学，并可以提高加工性能。报告的好处包括： 减少加工力；提高表面光洁度和形状精度；抑制毛刺形成；减少刀具磨损并延长刀具寿命；等。在车削过程中，由于刀具是静止的，振动辅助相对容易实现。一维振动辅助系统，即切削方向上的线性振动辅助，和二维振动辅助系统，即切削方向和切削深度方向平面上的椭圆振动运动，都已成功应用于车削加工。由于铣削过程的运动学和动力学的复杂性，振动辅助在铣削中的应用很少受到关注。目前振动辅助铣削方面的研究纯粹是经验性的，缺乏精确的运动学和动力学模型来设计最佳的 VAM 系统，并且所有 2D 振动辅助铣削研究都仅限于低频，不适用于微铣削操作。此外，为了获得复杂的形状几何形状，铣削过程需要空间中任意方向的进给矢量，即进给矢量的垂直和水平分量对于3D端铣削来说都是必需的。然而，目前还没有3D VAM系统的报道。为了克服现有技术的这些限制并利用振动辅助的优势，该项目将开发一种新型紧凑型3D振动辅助加工系统，用于难加工材料上自由曲面的微铣削，并通过加工实验评估其性能。在生物工程、MEMS、光学等各种应用中，对半导体材料、压电材料、玻璃等难加工材料制造精密微型产品的需求越来越大。该项目的成功将为以更具成本效益的方式加工此类材料开辟新的工业途径。然而，为了在实践中实现这一目标，迫切需要开发 3D 振动辅助加工系统及其相关的设计和建模方法。

项目成果

Finite element simulation and experimental investigation on cutting mechanism in vibration-assisted micro-milling

• DOI: 10.1007/s00170-019-03402-0
• 发表时间: 2019-12-01
• 期刊: INTERNATIONAL JOURNAL OF ADVANCED MANUFACTURING TECHNOLOGY
• 影响因子: 3.4
• 作者: Chen, Wanqun;Zheng, Lu;Huo, Dehong
• 通讯作者: Huo, Dehong

Modelling and experimental investigation on textured surface generation in vibration-assisted micro-milling

• DOI: 10.1016/j.jmatprotec.2018.11.011
• 发表时间: 2019-04
• 期刊: Journal of Materials Processing Technology
• 影响因子: 6.3
• 作者: Wanqun Chen;Lu Zheng;W. Xie;Kai Yang;D. Huo

Surface texture formation by non-resonant vibration assisted micro milling

非共振辅助微铣削形成表面纹理

• DOI: 10.1088/1361-6439/aaa06f
• 发表时间: 2018-02-01
• 期刊: JOURNAL OF MICROMECHANICS AND MICROENGINEERING
• 影响因子: 2.3
• 作者: Chen, Wanqun;Zheng, Lu;Chen, Yiwu
• 通讯作者: Chen, Yiwu

Modelling of the Influence of Tool Runout on Surface Generation in Micro Milling

• DOI: 10.1186/s10033-019-0318-x
• 发表时间: 2019-01-23
• 期刊: CHINESE JOURNAL OF MECHANICAL ENGINEERING
• 影响因子: 4.2
• 作者: Chen, Wanqun;Sun, Yazhou;Teng, Xiangyu
• 通讯作者: Teng, Xiangyu

A forward closed-loop virtual simulation system for milling process considering dynamics processing-machine interactions

• DOI: 10.1007/s00170-019-04057-7
• 发表时间: 2019-07
• 期刊: The International Journal of Advanced Manufacturing Technology
• 作者: Wanqun Chen;Z. Tong;D. Huo;Wenbin Zhong;X. Jiang