Effect of Duty Cycle on Cutting Force for Ultrasonic Vibration-Assisted Milling Carbon Fiber-Reinforced Polymer Laminates
Abstract
:1. Introduction
2. Theoretical Calculation of Duty Cycle for UVAM
2.1. Kinematic Analysis of Tool Motion Trajectory
2.2. Theoretical Investigation of Duty Cycle
2.3. Effect of Process Parameters on the Duty Cycle
3. UVAM Cutting Force Experiment
4. Results and Discussion
5. Conclusions
- UVAM significantly reduces the cutting force during CFRP machining. In this study, UVAM achieved a maximum reduction of 27% in the cutting force.
- The reduction rate of the cutting force in UVAM is related to the duty cycle. A larger duty cycle results in a shorter tool–workpiece separation time, which leads to UVAM and CM having closer cutting forces and a smaller reduction rate in the cutting force.
- The duty cycle is influenced by the spindle speed, tool diameter, tool helix angle, ultrasonic amplitude, and ultrasonic frequency. Increasing the spindle speed and tool diameter will increase the duty cycle, while increasing the tool helix angle, ultrasonic amplitude, and ultrasonic frequency will decrease the duty cycle.
- To maximize the effect of UVAM in reducing the cutting force, it is recommended to reduce the duty cycle while ensuring the requirements of the machining process parameters. This can be achieved by reducing the spindle speed or tool diameter and increasing the tool helix angle, ultrasonic amplitude, or ultrasonic frequency.
Author Contributions
Funding
Institutional Review Board Statement
Informed Consent Statement
Data Availability Statement
Conflicts of Interest
References
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Number | |||
---|---|---|---|
1 | 50, 100, 200 | 0.5 | 500, 1000 |
2 | 100 | 0.3, 0.7, 1 | 500, 1000 |
3 | 100 | 0.5 | 2000, 3000 |
No. | |||||||||||
Fx | Fy | Fx | Fy | ||||||||
CM | UVAM | CM | UVAM | CM | UVAM | CM | UVAM | ||||
1 | 50 | 0.5 | 500 | 18.64 | 13.81 | 25.73 | 22.99 | 6.08 | 5.91 | 9.46 | 9.75 |
2 | 100 | 0.5 | 500 | 23.52 | 19.25 | 25.27 | 23.28 | 7.90 | 7.39 | 10.23 | 10.03 |
3 | 200 | 0.5 | 500 | 32.67 | 27.30 | 30.35 | 26.70 | 12.22 | 11.53 | 12.51 | 12.20 |
4 | 50 | 0.5 | 1000 | 15.56 | 12.95 | 24.85 | 22.71 | 5.02 | 4.83 | 9.34 | 9.29 |
5 | 100 | 0.5 | 1000 | 18.14 | 15.26 | 23.89 | 21.61 | 5.83 | 5.66 | 8.18 | 8.16 |
6 | 200 | 0.5 | 1000 | 22.74 | 19.32 | 29.11 | 27.23 | 9.42 | 9.29 | 11.35 | 11.39 |
7 | 100 | 0.3 | 500 | 15.87 | 11.57 | 23.35 | 20.85 | 8.46 | 7.38 | 11.45 | 10.89 |
9 | 100 | 0.7 | 500 | 31.03 | 25.11 | 32.68 | 30.26 | 17.77 | 16.44 | 17.74 | 17.52 |
10 | 100 | 1 | 500 | 40.33 | 32.16 | 34.32 | 31.57 | 23.71 | 22.23 | 18.50 | 18.33 |
11 | 100 | 0.3 | 1000 | 13.39 | 10.92 | 22.29 | 19.03 | 5.90 | 5.59 | 9.45 | 9.50 |
12 | 100 | 0.7 | 1000 | 24.57 | 21.52 | 29.39 | 31.29 | 12.77 | 12.04 | 16.15 | 16.03 |
13 | 100 | 1 | 1000 | 32.31 | 28.30 | 32.34 | 33.88 | 16.78 | 15.81 | 16.60 | 16.45 |
14 | 100 | 0.5 | 2000 | 14.51 | 13.24 | 21.12 | 20.62 | 5.83 | 5.66 | 8.18 | 8.16 |
15 | 100 | 0.5 | 3000 | 12.05 | 11.66 | 17.12 | 17.90 | 5.09 | 5.20 | 7.77 | 8.11 |
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Zhang, Y.; Ren, J.; Zhou, J. Effect of Duty Cycle on Cutting Force for Ultrasonic Vibration-Assisted Milling Carbon Fiber-Reinforced Polymer Laminates. Materials 2023, 16, 7457. https://doi.org/10.3390/ma16237457
Zhang Y, Ren J, Zhou J. Effect of Duty Cycle on Cutting Force for Ultrasonic Vibration-Assisted Milling Carbon Fiber-Reinforced Polymer Laminates. Materials. 2023; 16(23):7457. https://doi.org/10.3390/ma16237457
Chicago/Turabian StyleZhang, Yukun, Junxue Ren, and Jinhua Zhou. 2023. "Effect of Duty Cycle on Cutting Force for Ultrasonic Vibration-Assisted Milling Carbon Fiber-Reinforced Polymer Laminates" Materials 16, no. 23: 7457. https://doi.org/10.3390/ma16237457