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The International Journal of Advanced Manufacturing Technology

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19-07-2019 | ORIGINAL ARTICLE

Rotary ultrasonic machining of carbon fiber–reinforced plastic composites: effects of ultrasonic frequency

Authors: Hui Wang, Yingbin Hu, Weilong Cong, Anthony R. Burks

Published in: The International Journal of Advanced Manufacturing Technology | Issue 9-12/2019

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Abstract

Rotary ultrasonic machining (RUM) is effective and efficient in cutting carbon fiber–reinforced plastic (CFRP) composites. With ultrasonic vibration assistance, both machining efficiency and machining effectiveness can be improved. Ultrasonic vibration has two major variables (including ultrasonic amplitude and ultrasonic frequency), which play important roles in RUM processes. Other intermediate variables, such as ultrasonic power and indentation depth, are directly related to these two variables. Effects of ultrasonic vibration amplitude have been extensively investigated in RUM hole making and surface machining processes. However, the effects of ultrasonic frequency in RUM have not been reported. The effects of ultrasonic frequency under different combinations of tool rotation speed, feed rate, and depth of cut on output variables, including cutting forces, surface roughness, and machined surface characteristics, are investigated, for the first time, in this study. The critical frequency is analyzed for the RUM process. Three different levels of ultrasonic frequencies are generated and applied to the RUM process. The kinematic motions of abrasive grains in RUM with different frequencies are analyzed and discussed. The results show that RUM with higher frequency of ultrasonic vibration is a more effective machining process, leading to cutting force reduction and the machined surface quality improvement.

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Title: Rotary ultrasonic machining of carbon fiber–reinforced plastic composites: effects of ultrasonic frequency
Authors: Hui Wang
Yingbin Hu
Weilong Cong
Anthony R. Burks
Publication date: 19-07-2019
Publisher: Springer London
Published in: The International Journal of Advanced Manufacturing Technology / Issue 9-12/2019
Print ISSN: 0268-3768
Electronic ISSN: 1433-3015
DOI: https://doi.org/10.1007/s00170-019-04084-4

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