Green ceramic machining benefits through ultrasonic-assisted turning: an experimental investigation

Detalhes bibliográficos
Autor(a) principal: Júnior, Marcos Gonçalves [UNESP]
Data de Publicação: 2022
Outros Autores: França, Thiago Valle [UNESP], Fortulan, Carlos Alberto, da Silva, Rodrigo Henriques Lopes, Foschini, Cesar Renato [UNESP]
Tipo de documento: Artigo
Idioma: eng
Título da fonte: Repositório Institucional da UNESP
Texto Completo: http://dx.doi.org/10.1007/s00170-021-08174-0
http://hdl.handle.net/11449/233644
Resumo: Machining of advanced ceramics in the green state aims to achieve complex geometry with near-net-shape dimensions minimizing machining steps after sintering, good surface finish, economic efficiency and flexibility, and reduced process costs, in addition to the removal of the outer layer with potential defects and prior correction of distortions expected during sintering. However, the pressure exerted by the cutting edge plus the removal of lumps can introduce damage such as chipping to the green part due to its low mechanical strength, especially with inappropriate cutting parameters. Ultrasonic-assisted machining on the cutting tool has been applied to improve machining performance by improving surface finish, reducing machining forces, and reducing tool wear. This paper proposes a study on ultrasonic-assisted turning (UAT) of ceramic materials in a green state where a flexure hinge was developed for allowing tool vibration only toward the depth of cut direction. A central composite design of experiments (DOE) with a full factorial design was performed to determine the proper condition of the cutting parameters. The results showed that the UAT on ceramic materials in a green state compared to conventional turning (CT) provided process benefits through improved surface finish due to reduced lump pull-outs, decreased tool flank wear by 34%, and reduced machining forces (10%). Finally, ultrasonic vibration promoted intermittent part-tool contact releasing the removed debris, which increases material removal at the chip-tool interface and consequently diminishes material adhesion on the tool.
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spelling Green ceramic machining benefits through ultrasonic-assisted turning: an experimental investigationAdvanced ceramicsGreen machiningMachining forcesUltrasonic-assisted turningMachining of advanced ceramics in the green state aims to achieve complex geometry with near-net-shape dimensions minimizing machining steps after sintering, good surface finish, economic efficiency and flexibility, and reduced process costs, in addition to the removal of the outer layer with potential defects and prior correction of distortions expected during sintering. However, the pressure exerted by the cutting edge plus the removal of lumps can introduce damage such as chipping to the green part due to its low mechanical strength, especially with inappropriate cutting parameters. Ultrasonic-assisted machining on the cutting tool has been applied to improve machining performance by improving surface finish, reducing machining forces, and reducing tool wear. This paper proposes a study on ultrasonic-assisted turning (UAT) of ceramic materials in a green state where a flexure hinge was developed for allowing tool vibration only toward the depth of cut direction. A central composite design of experiments (DOE) with a full factorial design was performed to determine the proper condition of the cutting parameters. The results showed that the UAT on ceramic materials in a green state compared to conventional turning (CT) provided process benefits through improved surface finish due to reduced lump pull-outs, decreased tool flank wear by 34%, and reduced machining forces (10%). Finally, ultrasonic vibration promoted intermittent part-tool contact releasing the removed debris, which increases material removal at the chip-tool interface and consequently diminishes material adhesion on the tool.Department of Mechanical Engineering São Paulo State University (Unesp)Department of Mechanical Engineering University of São Paulo (USP)Department of Mechanical Engineering Federal Technological University of ParanáDepartment of Mechanical Engineering São Paulo State University (Unesp)Universidade Estadual Paulista (UNESP)Universidade de São Paulo (USP)Federal Technological University of ParanáJúnior, Marcos Gonçalves [UNESP]França, Thiago Valle [UNESP]Fortulan, Carlos Albertoda Silva, Rodrigo Henriques LopesFoschini, Cesar Renato [UNESP]2022-05-01T09:31:05Z2022-05-01T09:31:05Z2022-02-01info:eu-repo/semantics/publishedVersioninfo:eu-repo/semantics/article3091-3104http://dx.doi.org/10.1007/s00170-021-08174-0International Journal of Advanced Manufacturing Technology, v. 118, n. 9-10, p. 3091-3104, 2022.1433-30150268-3768http://hdl.handle.net/11449/23364410.1007/s00170-021-08174-02-s2.0-85116781133Scopusreponame:Repositório Institucional da UNESPinstname:Universidade Estadual Paulista (UNESP)instacron:UNESPengInternational Journal of Advanced Manufacturing Technologyinfo:eu-repo/semantics/openAccess2024-06-28T13:54:39Zoai:repositorio.unesp.br:11449/233644Repositório InstitucionalPUBhttp://repositorio.unesp.br/oai/requestopendoar:29462024-08-05T16:22:28.687026Repositório Institucional da UNESP - Universidade Estadual Paulista (UNESP)false
dc.title.none.fl_str_mv Green ceramic machining benefits through ultrasonic-assisted turning: an experimental investigation
title Green ceramic machining benefits through ultrasonic-assisted turning: an experimental investigation
spellingShingle Green ceramic machining benefits through ultrasonic-assisted turning: an experimental investigation
Júnior, Marcos Gonçalves [UNESP]
Advanced ceramics
Green machining
Machining forces
Ultrasonic-assisted turning
title_short Green ceramic machining benefits through ultrasonic-assisted turning: an experimental investigation
title_full Green ceramic machining benefits through ultrasonic-assisted turning: an experimental investigation
title_fullStr Green ceramic machining benefits through ultrasonic-assisted turning: an experimental investigation
title_full_unstemmed Green ceramic machining benefits through ultrasonic-assisted turning: an experimental investigation
title_sort Green ceramic machining benefits through ultrasonic-assisted turning: an experimental investigation
author Júnior, Marcos Gonçalves [UNESP]
author_facet Júnior, Marcos Gonçalves [UNESP]
França, Thiago Valle [UNESP]
Fortulan, Carlos Alberto
da Silva, Rodrigo Henriques Lopes
Foschini, Cesar Renato [UNESP]
author_role author
author2 França, Thiago Valle [UNESP]
Fortulan, Carlos Alberto
da Silva, Rodrigo Henriques Lopes
Foschini, Cesar Renato [UNESP]
author2_role author
author
author
author
dc.contributor.none.fl_str_mv Universidade Estadual Paulista (UNESP)
Universidade de São Paulo (USP)
Federal Technological University of Paraná
dc.contributor.author.fl_str_mv Júnior, Marcos Gonçalves [UNESP]
França, Thiago Valle [UNESP]
Fortulan, Carlos Alberto
da Silva, Rodrigo Henriques Lopes
Foschini, Cesar Renato [UNESP]
dc.subject.por.fl_str_mv Advanced ceramics
Green machining
Machining forces
Ultrasonic-assisted turning
topic Advanced ceramics
Green machining
Machining forces
Ultrasonic-assisted turning
description Machining of advanced ceramics in the green state aims to achieve complex geometry with near-net-shape dimensions minimizing machining steps after sintering, good surface finish, economic efficiency and flexibility, and reduced process costs, in addition to the removal of the outer layer with potential defects and prior correction of distortions expected during sintering. However, the pressure exerted by the cutting edge plus the removal of lumps can introduce damage such as chipping to the green part due to its low mechanical strength, especially with inappropriate cutting parameters. Ultrasonic-assisted machining on the cutting tool has been applied to improve machining performance by improving surface finish, reducing machining forces, and reducing tool wear. This paper proposes a study on ultrasonic-assisted turning (UAT) of ceramic materials in a green state where a flexure hinge was developed for allowing tool vibration only toward the depth of cut direction. A central composite design of experiments (DOE) with a full factorial design was performed to determine the proper condition of the cutting parameters. The results showed that the UAT on ceramic materials in a green state compared to conventional turning (CT) provided process benefits through improved surface finish due to reduced lump pull-outs, decreased tool flank wear by 34%, and reduced machining forces (10%). Finally, ultrasonic vibration promoted intermittent part-tool contact releasing the removed debris, which increases material removal at the chip-tool interface and consequently diminishes material adhesion on the tool.
publishDate 2022
dc.date.none.fl_str_mv 2022-05-01T09:31:05Z
2022-05-01T09:31:05Z
2022-02-01
dc.type.status.fl_str_mv info:eu-repo/semantics/publishedVersion
dc.type.driver.fl_str_mv info:eu-repo/semantics/article
format article
status_str publishedVersion
dc.identifier.uri.fl_str_mv http://dx.doi.org/10.1007/s00170-021-08174-0
International Journal of Advanced Manufacturing Technology, v. 118, n. 9-10, p. 3091-3104, 2022.
1433-3015
0268-3768
http://hdl.handle.net/11449/233644
10.1007/s00170-021-08174-0
2-s2.0-85116781133
url http://dx.doi.org/10.1007/s00170-021-08174-0
http://hdl.handle.net/11449/233644
identifier_str_mv International Journal of Advanced Manufacturing Technology, v. 118, n. 9-10, p. 3091-3104, 2022.
1433-3015
0268-3768
10.1007/s00170-021-08174-0
2-s2.0-85116781133
dc.language.iso.fl_str_mv eng
language eng
dc.relation.none.fl_str_mv International Journal of Advanced Manufacturing Technology
dc.rights.driver.fl_str_mv info:eu-repo/semantics/openAccess
eu_rights_str_mv openAccess
dc.format.none.fl_str_mv 3091-3104
dc.source.none.fl_str_mv Scopus
reponame:Repositório Institucional da UNESP
instname:Universidade Estadual Paulista (UNESP)
instacron:UNESP
instname_str Universidade Estadual Paulista (UNESP)
instacron_str UNESP
institution UNESP
reponame_str Repositório Institucional da UNESP
collection Repositório Institucional da UNESP
repository.name.fl_str_mv Repositório Institucional da UNESP - Universidade Estadual Paulista (UNESP)
repository.mail.fl_str_mv
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