Chatter stability of robotic rotary ultrasonic countersinking

In recent years,industrial robots have received extensive attention in manufacturing field due to their high flexibility and great workspace.However,the weak stiffness of industrial robots makes it extremely easy to arouse chatter,which affects machining quality inevitably and generates noise pollution in severe cases.Compared with drilling,the chatter mechanism of robotic countersinking is more complex.The external excitation changes with cutting width and depth in countersinking.This characteristic results in time-varying and nonlinearity of robotic countersinking dynamics.Thus,it is urgent to propose a new method of chatter suppression and provide an accurate stability analysis model.As a new special machining technology,rotary ultrasonic machining has been proved to improve robotic drilling and milling stability effectively.Based on this,robotic rotary ultrasonic countersinking(RRUC)is proposed to improve the robotic countersinking stability in this paper.A three-dimensional stability domain method of RRUC is established.First,the countersinking process was divided intoρparts.The dynamic model of every unit was constructed based on ultrasonic function angle(γ)and dynamic chip area.Then,the stability region of RRUC is obtained based on the semi-discrete method(SDM).Compared with the robotic conventional countersinking(RCC),RRUC improves the stability by 27%.Finally,the correctness and effectiveness of the stability region model are proved by robotic ultrasonic countersinking experiments.

Experimental study and optimization of cutting parameters in machining of super alloy with hybrid ultrasonic method

Super alloys are intensively used in various industries, especially in the aerospace industry, because of their special characteristics. A number of holes are sometimes required to be drilled into super alloys for aircraft at their final stage assembly. In the present study, a hybrid ultrasonic machining method, called rotary ultrasonic machining （RUM）, was successfully used in super alloy drilling. The empirical modeling of the process parameters of RUM was performed for the super alloy （Inconel 718） using an experimental design approach, called response surface methodology （RSM）. Parameters, namely tool rotation, feed rate, ultrasonic power, and abrasive grit size, were selected as input variables. The others were kept constant. The performance was measured in terms of the machining rate and the surface roughness. The developed models were found to be reliable representatives of the experimental results with prediction errors less than 4-5%. Moreover, the feed rate for the quality and productivity aspect was found to be the most critical factor. The optimized values of the machining rate and the surface roughness achieved through a multi-response optimization were 0.9 825 mm3/s and 0.951 i.tm, respectively.

Modeling the optimal compensation capacitance of a giant magnetostrictive ultrasonic transducer with a loosely-coupled contactless power transfer system

The giant magnetostrictive rotary ultrasonic processing system(GMUPS)with a loosely-coupled contactless power transfer(LCCPT)has emerged as a high-performance technique for the processing of hard and brittle materials,owing to its high power density.A capacitive compensation is required to achieve the highest energy efficiency of GMUPS to provide sufficient vibration amplitude when it works in the resonance state.In this study,an accurate model of the optimal compensation capacitance is derived from a new electromechanical equivalent circuit model of the GMUPS with LCCPT,which consists of an equivalent mechanical circuit and an electrical circuit.The phase lag angle between the mechanical and electrical circuits is established,taking into account the non-negligible loss in energy conversion of giant magnetostrictive material at ultrasonic frequency.The change of system impedance characteristics and the effectiveness of the system compensation method under load are analyzed.Both idle vibration experiments and machining tests are conducted to verify the developed model.The results show that the GMUPS with optimal compensation capacitance can achieve the maximum idle vibration amplitude and smallest cutting force.In addition,the effects of magnetic conductive material and driving voltages on the phase lag angle are also evaluated.