HYBRID MICRO-MACHINING PROCESSES WITH ULTRASONIC ASSISTANCE: A REVIEW
Keywords:
Hybrid micro-machining, ultrasonic assistance, vibration, hybrid ultrasonic machining
Abstract
The paper deals with the main nonconventional hybrid micro-machining processes with ultrasonic assistance, starting from basic nonconventional technologies. In introduction, some hybrid processes were presented, like vibration, laser, fluid, magnetic and external electric fields, or carbon nanofibre assisted micro-machining. The study details the means of ultrasonic vibrations were applied, i.e., by vibrating the tool, workpiece or working fluid, and also the effect on output (technological) process parameters, mainly the machinability and removal rate for specific machined material. A comparison was made between the results obtained using classic electrical discharge machining (EDM) and ultrasonically aided EDM (EDM+US). In this case, the surface roughness, the machining rate, and the volumetric relative wear were studied. Finally, the advantages and disadvantages were exposed, and some solutions of output technological parameters for further improvement.
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40. De Silva, A.K.M., Pajak, P.T., McGeough, J.A., Harrison, D.K., Thermal effects in laser assisted jet electrochemical machining, CIRP Ann. Manuf. Technol., 60(1), pp. 243-246, (2011).
41. Kaakkunen J., Silvennoinen M, Paivasaari K, Vahimaa P., Water-assisted femtosecond laser pulse ablation of high aspect ratio holes, Phys Procedia, Vol. 12, pp. 89-93, (2011).
2. Wit Grzesik, Hybrid machining processes. Definitions, generation rules and real industrial importance, Mechanik, Vol.91, No.5-6, pp. 338-342, (2018).
3. Lauwers B., Klocke F., Klink A., Tekkaya A.E., Neugebauer R., Mc Intosh D., Hybrid processes in manufacturing, Annals of the CIRP Manufacturing Technology, 63, Vol. 2, pp. 561-583, (2014).
4. Lauwers B., Surface Integrity in Hybrid Machining Processes, Procedia Engineering 19, pp. 241-251, (2011).
5. Sumit Bhowmik, Divya Zindani, Hybrid Micro-Machining Processes, ISBN 978-3-030-13039-8, Springer, India, pp. 50-51, (2019).
6. D.E. Brehl, T.A. Dow, Review of vibration-assisted machining, Precis. Eng. 32(3), pp. 153-172 (2008).
7. T. Tawakoli, B. Azarhoushang, M. Rabiey, Ultrasonic assisted dry grinding of 42CrMo4, Int. J. Adv. Manuf. Technol. 42(9-10), pp. 883-891, (2009).
8. B. Azarhoushang, J. Akbari, Ultrasonic-assisted drilling of Inconel 738-LC, Int. J. Mach. Tools
Manuf. 47(7–8), pp. 1027-1033, (2007).
9. Deepak Rajendra Unune and Harlal Singh Mali, Current status and applications of hybrid micro-machining processes: A review, Journal of Engineering Manufacture, Vol. 229, pp. 1681-1693, (2014).
10. P. Mukhopadhyay, B.R. Sarkar, Advancement in ultrasonic vibration and magnetic field assisted micro-EDM process: An overview, IJARET, (2019).
11. Bharat, C Khatri, Pravin, Rathid and Janak B Valaki, Ultrasonic vibration-assisted electric discharge machining: A research review, Journal of Engineering Manufacture I - I2, (2015).
12. Gao, C and Liu, Z., A study of ultrasonically aided microelectrical-discharge machining by the application of workpiece vibration, J Mater Process Tech, pp. 226-228, (2003).
13. Hoang, KT and Yang, SH., A study on the effect of different vibration-assisted methods in micro-WEDM, J Mater Process Tech, pp. 1616-1622, (2013).
14. Prihandana, GS, Mahardika M, Hamdi M, et al., Effect of micro-powder suspension and ultrasonic vibration of dielectric fluid in micro-EDM processes - Taguchi approach., Int J Mach Tool Manu., pp. 1035-1041, (2009).
15. Schubert, A, Zeidler H, Hackert, et al., Enhancing micro-EDM using ultrasonic vibration and approaches for machining of non-conducting ceramics, J Mech Eng, pp. 156-164, (2013).
16. Ghiculescu, D, Marinescu, NI and Nanu, S., Equipment for ultrasonic aiding of wire electrodischarge machining, Acad J Manuf Eng, pp. 18-23, (2011).
17. Saeed Zare Chavoshi, Xichuan Luo, Hybrid micro-machining processes: A review, Precision Engineering 41, pp. 1-23, (2015).
18. Hassan El-Hofy, McGraw-Hill Companies, Advanced Machining Processes, Nontraditional and hybrid machining processes, Production Engineering Department Alexandria University, Egypt, (2005).
19. Yufeng Wang, Zheng Zhang et. al., Study on immersion waterjet assisted laser micromachining process, Journal of Materials Processing Tech. 262, pp. 290-298, (2018).
20. J. Ramkumar, Mahavir Singh, Overview of Hybrid Machining Processes (HMPs), Micromanufacturing Lab., I.I.T. Kanpur, Chapter 2.
21. Pa PS., Super finishing with ultrasonic and magnetic assistance in electro-chemical micro-machining, Electrochim Acta, 54:6022-7, (2009).
22. S. Kumar, C.S. Wu, et. al., Application of ultrasonic vibrations in welding and metal processing: A status review, Journal of Manufacturing Processes 26, pp. 295-322, (2017).
23. Kremer D, Lebrun JL, Hosari B, et al., Effects of ultrasonic vibrations on the performances in EDM, CIRP Ann: Manuf Techn, 38(1), pp. 199-202, (1989).
24. Guo ZN, Lee TC, Yue TM, et al., A study of ultrasonic aided wire electrical discharge machining, J Mater Process Tech, Vol. 63, pp. 823-828, (1997).
25. Yu ZY, Zhang Y, Li J, et al., High aspect ratio micro-hole drilling aided with ultrasonic vibration and planetary movement of electrode by micro-EDM, CIRP Ann: Manuf Techn, Vol. 58, pp. 213-216, (2009).
26. Tangwarodomnukun V, Wanga J, Huang CZ, Zhu HT, An investigation of hybrid laser-waterjet ablation of silicon substrates, Int J Mach Tools Manuf, Vol. 5, pp. 39-49, (2012).
27. Sezer HK, Li L, Leigh S., Twin gas jet-assisted laser drilling through thermal barrier-coated nickel alloy substrates, Int J Mach Tools Manuf, Vol. 49, pp. 26-35, (2009).
28. Jang D, Kim D., Liquid-assisted excimer laser micromaching for ablation enhancement and debris reduction, J Laser Micro/Nanoeng, 1(3):221-5, (2006).
29. Guo J, Morita SY, Hara M, Yamagata Y, Higuchi T., Ultra-precision finishing of micro-aspheric mold using a magnetostrictive vibrating polisher, CIRP Ann Manuf Technol, 61:371-4, (2012).
30. Zheng HY, Jiang ZW., Femtosecond laser micro-machining of silicon with an external electric field, J Micromech Microeng, 20:017001, (2010).
31. Liew PJ, Yan J, Kuriyagawa T., Carbon nanofiber assisted micro electro discharge machining of reaction-bonded silicon carbide, J Mater Process Technol, 213:1076–87, (2013).
32. Murthi VSR and Philip PK., A comparative analysis of machining characteristics in ultrasonic assisted EDM by the response surface methodology, Int J Prod Res, 25(2), pp. 259-272, (1987).
33. Lipchanskii AB., Experimental investigation of wire electrical discharge machining assisted with ultrasonic vibration, Sov Surf Eng Appl Electrochem, 1: 5-9, (1991).
34. Ichikawa T and Natsu W., Realization of micro-EDM under ultra-small discharge energy by applying ultrasonic vibration to machining fluid, Procedia CIRP, 6: 326-331, (2013).
35. Wee LM, Ng EYK, Prathama AH, Zheng H., Micro-machining of silicon wafer in air and under water., Opt Laser Technol, 43:62-71, (2011).
36. Tsai C-H, Li C-C., Investigation of underwater laser drilling for brittle sub-strates, J Mater Process Technol, 209:2838-46, (2009).
37. A.K.M. De Silva, P.T. Pajak, D.K. Harrison, J.A. McGeough, Modelling and experimental investigation of laser assisted jet electrochemical machining, CIRP Ann. Manuf. Technol., 53(1), pp. 179-182, (2004).
38. P.T. Pajak, A.K.M. Desilva, D.K. Harrison, J.A. Mcgeough, Precision and efficiency of laser assisted jet electrochemical machining. Precis. Eng., 30(3), pp. 288-298, (2006).
39. A.K.M. De Silva, P.T. Pajak, J.A. McGeough, D.K. Harrison, Thermal effects in laser assisted jet electrochemical machining, CIRP Ann. Manuf. Technol., 60(1), pp. 243-246, (2011).
40. De Silva, A.K.M., Pajak, P.T., McGeough, J.A., Harrison, D.K., Thermal effects in laser assisted jet electrochemical machining, CIRP Ann. Manuf. Technol., 60(1), pp. 243-246, (2011).
41. Kaakkunen J., Silvennoinen M, Paivasaari K, Vahimaa P., Water-assisted femtosecond laser pulse ablation of high aspect ratio holes, Phys Procedia, Vol. 12, pp. 89-93, (2011).
Published
2021-12-31
How to Cite
Enciu, C., Parvu (Ene), G., & Ghiculescu, L. (2021). HYBRID MICRO-MACHINING PROCESSES WITH ULTRASONIC ASSISTANCE: A REVIEW. Nonconventional Technologies Review, 25(4). Retrieved from https://www.revtn.ro/index.php/revtn/article/view/359
Section
Articles
Copyright (c) 2021 Cornel Cristian Enciu, Gabriela Parvu (Ene), Liviu Daniel Ghiculescu
This work is licensed under a Creative Commons Attribution-NoDerivatives 4.0 International License.
