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Investigation on self-sensing monitoring and resonant control of ultrasonic vibration–assisted cutting

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Abstract

Ultrasonic elliptical vibration-assisted cutting is a precision machining method that improves the surface quality, reduces burrs, and prolongs the life of the tool. However, during the cutting process, the natural frequency of ultrasonic vibration varies with cutting force and contact conditions, which makes the amplitude of the vibration shrink greatly. Consequently, to resist the influence of cutting loads and unpredictable disturbances in the cutting process, an innovative strategy available to stabilize frequency and amplitude with an electro-mechanical conversion model considering hysteresis compensation was proposed. The proposed model is specially designed for the high-frequency ultrasonic vibration device in the actual machining process. First, to compensate for errors caused by the hysteresis nonlinearity in the ultrasonic vibration processing, a method using the Prandtl-Ishlinskii operator to model the hysteresis effect of the ultrasonic device was proposed. The advantage of this method is that it can quickly adapt to the changes in the hysteresis effect of ultrasonic equipment in real time based on the reversible analytical solution of the Prandtl-Ishlinskii operator. Second, a self-sensing circuit was developed to monitor the cutting process of the ultrasonic vibration cutting actuator in real time, which can measure the electrical signal of the piezoelectric ceramic. With a reference to the piezoelectric hysteresis model, a self-sensing model for calculating the amplitude of ultrasonic vibration devices based on electrical signals in real time was established. Finally, a control system to track and control the frequency and amplitude of the ultrasonic vibration process was developed, and the experimental test and the micro-surface cutting experiment of this control system were carried out. It can be seen from the result that the frequency and amplitude of ultrasonic vibration are more robust by using the self-sensing control system, and a significant reduction of 11.47% in the circumferential length error of the machined workpiece was observed.

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Acknowledgements

The authors are thankful to reviewers for their comments and suggestions to improve the quality of the manuscript.

Funding

The work in this paper was supported by the National Natural Science Foundation of China (NSFC) under Grant Number 51675277 and by the High-Level Talents Project of “Six Talents Summit” in Jiangsu under Grant Number GDZB-011.

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Authors and Affiliations

  1. Nanjing University of Aeronautics and Astronautics, Nanjing, 210016, China

    Fuhang Yu, Chen Zhang, Xiaoming Gan & Xin Hu

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  1. Fuhang Yu
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  2. Chen Zhang
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  3. Xiaoming Gan
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  4. Xin Hu
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Contributions

Fuhang Yu: hysteresis compensation, experiments, data collection, and manuscript writing. Chen Zhang: methodology, concept, and thought guide. Xiaoming Gan: control mothed and experiments. Xin Hu: experiments and data processing. All authors read and reviewed the manuscript.

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Correspondence to Chen Zhang.

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Yu, F., Zhang, C., Gan, X. et al. Investigation on self-sensing monitoring and resonant control of ultrasonic vibration–assisted cutting. Int J Adv Manuf Technol 125, 2435–2453 (2023). https://doi.org/10.1007/s00170-023-10873-9

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  • DOI: https://doi.org/10.1007/s00170-023-10873-9

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