Skip to main content
SpringerLink
Log in

Research into the transition of material removal mechanism for C/SiC in rotary ultrasonic face machining

  • ORIGINAL ARTICLE
  • Published:
The International Journal of Advanced Manufacturing Technology Aims and scope Submit manuscript

Abstract

Ceramic matrix composites of type C/SiC with superior properties have got increasing importance in many fields of industry, especially in the aerospace area. Rotary ultrasonic machining is a high-efficiency processing technology for these advanced materials. However, due to the inhomogeneity and anisotropy of these composites, the machining process is still challenging to achieve desired result due to the lack of understanding and control of material removal mechanism. In this paper, the maximum depth of penetration by diamond abrasives in workpiece material is proposed to quantify the material removal modes. A model of maximum depth of penetration for rotary ultrasonic face machining (RUFM) was developed based on the indentation theory. An experimental RUFM of C/SiC was carried out, and it revealed that the material removal mechanism transited from ductile mode to brittle fracture mode with the decrease of cutting speed. Similar transition was observed with the increase of feed rate and cutting depth. By comparing the measured cutting force with simulation, a critical depth of penetration for the cutting mechanism transition was defined at about 4 μm. The processed surface topography was studied, and the transition of material removal modes was identified by the sudden change of the 3D surface roughness map at the critical penetration depth. Thus, the maximum depth of penetration model developed in this paper can be applied to identify the ductile or brittle fracture removal mode in RUFM of C/SiC using the cutting parameters. This allows controlling the material removal mechanism to achieve desired machining efficiency and quality.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Log in via an institution

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Institutional subscriptions

Similar content being viewed by others

References

  1. Bansal NP (2005) Handbook of ceramic composites. Springer, US. https://doi.org/10.1007/b104068

    Book  Google Scholar 

  2. Krenkel W, Berndt F (2005) C/C–SiC composites for space applications and advanced friction systems. Mater Sci Eng A 412(1–2):177–181. https://doi.org/10.1016/j.msea.2005.08.204

    Article  Google Scholar 

  3. M’Saoubi R, Axinte D, Soo SL, Nobel C, Attia H, Kappmeyer G, Engin S, Sim WM (2015) High performance cutting of advanced aerospace alloys and composite materials. CIRP Ann Manuf Technol 64(2):557–580. https://doi.org/10.1016/j.cirp.2015.05.002

    Article  Google Scholar 

  4. Klocke F, Soo SL, Karpuschewski B, Webster JA, Novovic D, Elfizy A, Axinte D, Tönissen S (2015) Abrasive machining of advanced aerospace alloys and composites. CIRP Ann Manuf Technol 64(2):581–604. https://doi.org/10.1016/j.cirp.2015.05.004

    Article  Google Scholar 

  5. Teti R (2002) Machining of composite materials. CIRP Ann Manuf Technol 51(2):611–634. https://doi.org/10.1016/S0007-8506(07)61703-X

    Article  Google Scholar 

  6. Hocheng H, Tai NH, Liu CS (2000) Assessment of ultrasonic drilling of C/SiC composite material. Compos Part A Appl S 31(2):133–142. https://doi.org/10.1016/S1359-835X(99)00065-2

    Article  Google Scholar 

  7. Li ZC, Jiao Y, Deines TW, Pei ZJ, Treadwell C (2005) Rotary ultrasonic machining of ceramic matrix composites: feasibility study and designed experiments. Int J Mach Tools Manuf 45(12):1402–1411. https://doi.org/10.1016/j.ijmachtools.2005.01.034

    Article  Google Scholar 

  8. Cong WL, Pei ZJ, Treadwell C (2014) Preliminary study on rotary ultrasonic machining of CFRP/Ti stacks. Ultrasonics 54(6):1594–1602. https://doi.org/10.1016/j.ultras.2014.03.012

    Article  Google Scholar 

  9. Cong WL, Pei ZJ, Sun X, Zhang CL (2014) Rotary ultrasonic machining of CFRP: a mechanistic predictive model for cutting force. Ultrasonics 54(2):663–675. https://doi.org/10.1016/j.ultras.2013.09.005

    Article  Google Scholar 

  10. Ning FD, Cong WL, Pei ZJ, Treadwell C (2015) Rotary ultrasonic machining of CFRP: a comparison with grinding. Ultrasonics 66:125–132. https://doi.org/10.1016/j.ultras.2015.11.002

    Article  Google Scholar 

  11. Pei ZJ, Ferreira PM, Kapoor SG, Haselkorn M (1995) Rotary ultrasonic machining for face milling of ceramics. Int J Mach Tools Manuf 35(7):1033–1046. https://doi.org/10.1016/0890-6955(94)00100-X

    Article  Google Scholar 

  12. Bertsche E, Ehmann K, Malukhin K (2013) An analytical model of rotary ultrasonic milling. Int J Adv Manuf Technol 65(9–12):1705–1720. https://doi.org/10.1007/s00170-012-4292-z

    Article  Google Scholar 

  13. Zhang C, Zhang J, Feng P (2013) Mathematical model for cutting force in rotary ultrasonic face milling of brittle materials. Int J Adv Manuf Technol 69(1–4):161–170. https://doi.org/10.1007/s00170-013-5004-z

    Article  Google Scholar 

  14. Xiao X, Zheng K, Liao W (2014) Theoretical model for cutting force in rotary ultrasonic milling of dental zirconia ceramics. Int J Adv Manuf Technol 75(9–12):1263–1277. https://doi.org/10.1007/s00170-014-6216-6

    Article  Google Scholar 

  15. Zhang C, Yuan S, Amin M, Fan H, Liu Q (2016) Development of a cutting force prediction model based on brittle fracture for C/SiC in rotary ultrasonic facing milling. Int J Adv Manuf Technol 85(1–4):573–583. https://doi.org/10.1007/s00170-015-7894-4

    Google Scholar 

  16. Yuan S, Fan H, Amin M, Zhang C, Guo M (2016) A cutting force prediction dynamic model for side milling of ceramic matrix composites C/SiC based on rotary ultrasonic machining. Int J Adv Manuf Technol 86(1–4):37–48. https://doi.org/10.1007/s00170-015-8099-6

    Article  Google Scholar 

  17. Zhang QH, Wu CL, Sun JL, Jia ZX (2000) The mechanism of material removal in ultrasonic drilling of engineering ceramics. Proc Inst Mech Eng B J Eng Manuf 214(9):805–810. https://doi.org/10.1243/0954405001517874

    Article  Google Scholar 

  18. Liu DF, Cong WL, Pei ZJ, Tang YJ (2012) A cutting force model for rotary ultrasonic machining of brittle materials. Int J Mach Tools Manuf 52(1):77–84. https://doi.org/10.1016/j.ijmachtools.2011.09.006

    Article  Google Scholar 

  19. Ding K, Fu Y, Su H, Chen Y, Yu X, Ding G (2014) Experimental studies on drilling tool load and machining quality of C/SiC composites in rotary ultrasonic machining. J Mater Process Tech 214(12):2900–2907. https://doi.org/10.1016/j.jmatprotec.2014.06.015

    Article  Google Scholar 

  20. Yuan S, Zhang C, Amin M (2015) Development of a cutting force prediction model based on brittle fracture for carbon fiber reinforced polymers for rotary ultrasonic drilling. Int J Adv Manuf Technol 81(5–8):1223–1231. https://doi.org/10.1007/s00170-015-7269-x

    Article  Google Scholar 

  21. Khoo CY, Hamzah E, Sudin I (2008) A review on the rotary ultrasonic machining of advanced ceramics. Jurnal Mekanikal 25:9–23

    Google Scholar 

  22. Pei ZJ, Ferreira PM, Haselkorn M (1995) Plastic flow in rotary ultrasonic machining of ceramics. J Mater Process Tech 48(1–4):771–777. https://doi.org/10.1016/0924-0136(94)01720-L

    Article  Google Scholar 

  23. Pei ZJ, Ferreira PM (1998) Modeling of ductile-mode material removal in rotary ultrasonic machining. Int J Mach Tools Manuf 38(10–11):1399–1418. https://doi.org/10.1016/S0890-6955(98)00007-8

    Article  Google Scholar 

  24. Zhang C, Feng P, Zhang J (2013) Ultrasonic vibration-assisted scratch-induced characteristics of C-plane sapphire with a spherical indenter. Int J MachTools Manuf 64:38–48. https://doi.org/10.1016/j.ijmachtools.2012.07.009

    Article  Google Scholar 

  25. Zhou M, Zhao P (2016) Prediction of critical cutting depth for ductile-brittle transition in ultrasonic vibration assisted grinding of optical glasses. Int J Adv Manuf Technol 86(5–8):1775–1784. https://doi.org/10.1007/s00170-015-8274-9

    Article  Google Scholar 

  26. Lv D, Tang Y, Wang H (2013) Experimental investigations on subsurface damage in rotary ultrasonic machining of glass BK7. Mach Sci Technol 17(3):443–463. https://doi.org/10.1080/10910344.2013.806114

    Article  Google Scholar 

  27. Pei ZJ, Ferreira PM (1999) An experimental investigation of rotary ultrasonic face milling. Int J Mach Tools Manuf 39(8):1327–1344. https://doi.org/10.1016/S0890-6955(98)00093-5

    Article  Google Scholar 

  28. Yuan S, Zhang C, Hu J (2015) Effects of cutting parameters on ductile material removal mode percentage in rotary ultrasonic face machining. Proc Inst Mech Eng B J Eng Manuf 229(9):1547–1556. https://doi.org/10.1177/0954405414548497

    Article  Google Scholar 

  29. Lawn BR, Evans AG, Marshall DB (1980) Elastic/plastic indentation damage in ceramics: the median/radial crack system. J Am Ceram Soc 63(9–10):574–581. https://doi.org/10.1111/j.1151-2916.1980.tb10768.x

    Article  Google Scholar 

  30. Brecher C, Schug R, Weber A, Wenzel C, Hannig S (2010) New systematic and time-saving procedure to design cup grinding wheels for the application of ultrasonic-assisted grinding. Int J Adv Manuf Technol 47(1):153–159. https://doi.org/10.1007/s00170-009-2204-7

    Article  Google Scholar 

Download references

Funding

This work was supported by the Basic Scientific Research Program of China and the International Scientific and Technological Cooperative Project between China and Russia [CR19-16]. The authors are indebted to this support to accomplish this research.

Author information

Authors and Affiliations

  1. School of Mechanical Engineering and Automation, Beijing Engineering Technological Research Center of High-efficient & Green CNC Machining Process and Equipment, Beihang University, Beijing, 100191, China

    Songmei Yuan & Zhen Li

  2. Aerospace Research Institute of Materials & Processing Technology, Beijing, 100076, China

    Chong Zhang

  3. Department of Mechanical Engineering, Bauman State Technical University, Moscow, 105005, Russia

    Alexander Guskov

Authors
  1. Songmei Yuan
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. Zhen Li
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. Chong Zhang
    View author publications

    You can also search for this author in PubMed Google Scholar

  4. Alexander Guskov
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding author

Correspondence to Songmei Yuan.

Electronic supplementary material

ESM 1

(DOCX 7443 kb).

Rights and permissions

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Yuan, S., Li, Z., Zhang, C. et al. Research into the transition of material removal mechanism for C/SiC in rotary ultrasonic face machining. Int J Adv Manuf Technol 95, 1751–1761 (2018). https://doi.org/10.1007/s00170-017-1332-8

Download citation

  • Received:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s00170-017-1332-8

Keywords

Search

Navigation