36
Remanufacturing and Advanced Machining
the maximum MRR of 18.97 mm 3 /min was achieved and surface roughness of
0.76 μm Ra was possible (Kang et al., 2006).
Efficiency of the process is proportional to the square fragility criterion, t x
2 , which
is the relation of shear strength of a material σ to normal stress applied τ. Materials
with t x > 2, such as glass, ceramics, silicon, or germanium, are the most effective
when subject to USM (Koryagin et al., 2000).
Devices for USM can be categorized as portable, of smaller power, and stationary, either universal or specialized. Typically, such a device consists of power supply, high-frequency generator, transducer, ultrasonic amplitude transformer (horn),
abrasive slurry supply system, tool, tool holder, fixture, and measurement devices for
machining depth assessment. Jain et al. (2011) distinguish microultrasonic machining and propose to categorize micro-USM units as stationary, microrotary USM,
and hybrid USM. The latter category includes USM + EDM, USM + AFM, and
ultrasonic-assisted turning and drilling in microscale.
Rotary ultrasonic machining (RUM) should be mentioned as an important hybrid
machining process that utilizes ultrasonic vibrations. This is a mechanical type of
nontraditional machining where the basic material removal phenomenon of ultrasonic machining and conventional diamond grinding amalgamates are combined.
As a result, a higher material removal rate and an improved hole accuracy with superior surface finish are achieved (Singh and Singhal, 2016). Moreover, the RUM technology has improved the surface quality of the workpiece, increased the processing
accuracy, prolonged the cutting tool life, and improved the processing efficiency by
up to ten times compared to traditional ultrasonic machining under similar conditions (Zhou et al. 2019).
In the ultrasonic vibration-assisted (UVA) machining processes, as shown in
Figure 1.9d, vibration is applied to either the cutting tool or the workpiece in order
to reduce the cutting force, cutting temperature, tool wear, cutting chip, and resulting surface roughness of the workpiece, as well as to increase cutting speed. UVA
machining modifies both traditional processes, such as UVA turning, UVA drilling, UVA grinding, and nontraditional ones, like UVA electrical discharge machining (EDM) and UVA laser beam machining (LBM) (Cong and Pei, 2013). The
UVA machining is most effective for cutting with small MRR, e.g., in threading.
When a thread cutting tool is excited with ultrasonic vibrations, momentum can
be reduced by 25 to 50% and the resultant thread surface is improved. In effect,
numbers of thread cutting tools may be reduced, improving efficiency of the entire
process 1.5 and even 3 times while excluding workpiece damage caused by broken
taps (Koryagin et al., 2000). Ultrasonic-assisted machining is commonly used for
machining of difficult-to-cut materials, especially for ultra-precision machining of
titanium alloys. To avoid surface damage and side burrs caused by vibration, a magnetic field can be introduced to ultrasonic-assisted diamond cutting, thus creating a
hybrid ultrasonic vibration and magnetic field-assisted diamond cutting process (Yip
et al., 2021).
Ultrasonic is also found useful in the ultrasonic surface treatment (UST) process.
The UST operation improves tribological properties of a material and fatigue life of
engineering systems by enhancing surface mechanical properties, such as roughness
Remanufacturing and Advanced Machining
the maximum MRR of 18.97 mm 3 /min was achieved and surface roughness of
0.76 μm Ra was possible (Kang et al., 2006).
Efficiency of the process is proportional to the square fragility criterion, t x
2 , which
is the relation of shear strength of a material σ to normal stress applied τ. Materials
with t x > 2, such as glass, ceramics, silicon, or germanium, are the most effective
when subject to USM (Koryagin et al., 2000).
Devices for USM can be categorized as portable, of smaller power, and stationary, either universal or specialized. Typically, such a device consists of power supply, high-frequency generator, transducer, ultrasonic amplitude transformer (horn),
abrasive slurry supply system, tool, tool holder, fixture, and measurement devices for
machining depth assessment. Jain et al. (2011) distinguish microultrasonic machining and propose to categorize micro-USM units as stationary, microrotary USM,
and hybrid USM. The latter category includes USM + EDM, USM + AFM, and
ultrasonic-assisted turning and drilling in microscale.
Rotary ultrasonic machining (RUM) should be mentioned as an important hybrid
machining process that utilizes ultrasonic vibrations. This is a mechanical type of
nontraditional machining where the basic material removal phenomenon of ultrasonic machining and conventional diamond grinding amalgamates are combined.
As a result, a higher material removal rate and an improved hole accuracy with superior surface finish are achieved (Singh and Singhal, 2016). Moreover, the RUM technology has improved the surface quality of the workpiece, increased the processing
accuracy, prolonged the cutting tool life, and improved the processing efficiency by
up to ten times compared to traditional ultrasonic machining under similar conditions (Zhou et al. 2019).
In the ultrasonic vibration-assisted (UVA) machining processes, as shown in
Figure 1.9d, vibration is applied to either the cutting tool or the workpiece in order
to reduce the cutting force, cutting temperature, tool wear, cutting chip, and resulting surface roughness of the workpiece, as well as to increase cutting speed. UVA
machining modifies both traditional processes, such as UVA turning, UVA drilling, UVA grinding, and nontraditional ones, like UVA electrical discharge machining (EDM) and UVA laser beam machining (LBM) (Cong and Pei, 2013). The
UVA machining is most effective for cutting with small MRR, e.g., in threading.
When a thread cutting tool is excited with ultrasonic vibrations, momentum can
be reduced by 25 to 50% and the resultant thread surface is improved. In effect,
numbers of thread cutting tools may be reduced, improving efficiency of the entire
process 1.5 and even 3 times while excluding workpiece damage caused by broken
taps (Koryagin et al., 2000). Ultrasonic-assisted machining is commonly used for
machining of difficult-to-cut materials, especially for ultra-precision machining of
titanium alloys. To avoid surface damage and side burrs caused by vibration, a magnetic field can be introduced to ultrasonic-assisted diamond cutting, thus creating a
hybrid ultrasonic vibration and magnetic field-assisted diamond cutting process (Yip
et al., 2021).
Ultrasonic is also found useful in the ultrasonic surface treatment (UST) process.
The UST operation improves tribological properties of a material and fatigue life of
engineering systems by enhancing surface mechanical properties, such as roughness