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Rotary ultrasonic machining of carbon fiber–reinforced plastic composites: effects of ultrasonic frequency

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Abstract

Rotary ultrasonic machining (RUM) is effective and efficient in cutting carbon fiber–reinforced plastic (CFRP) composites. With ultrasonic vibration assistance, both machining efficiency and machining effectiveness can be improved. Ultrasonic vibration has two major variables (including ultrasonic amplitude and ultrasonic frequency), which play important roles in RUM processes. Other intermediate variables, such as ultrasonic power and indentation depth, are directly related to these two variables. Effects of ultrasonic vibration amplitude have been extensively investigated in RUM hole making and surface machining processes. However, the effects of ultrasonic frequency in RUM have not been reported. The effects of ultrasonic frequency under different combinations of tool rotation speed, feed rate, and depth of cut on output variables, including cutting forces, surface roughness, and machined surface characteristics, are investigated, for the first time, in this study. The critical frequency is analyzed for the RUM process. Three different levels of ultrasonic frequencies are generated and applied to the RUM process. The kinematic motions of abrasive grains in RUM with different frequencies are analyzed and discussed. The results show that RUM with higher frequency of ultrasonic vibration is a more effective machining process, leading to cutting force reduction and the machined surface quality improvement.

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Funding

The work was supported by U.S. National Science Foundation through award CMMI-1538381.

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Authors and Affiliations

  1. Department of Industrial, Manufacturing, and Systems Engineering, Texas Tech University, Lubbock, TX, 79409, USA

    Hui Wang, Yingbin Hu & Weilong Cong

  2. Department of Electrical and Computer Engineering, Texas Tech University, Lubbock, TX, 79409, USA

    Anthony R. Burks

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Correspondence to Weilong Cong.

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Wang, H., Hu, Y., Cong, W. et al. Rotary ultrasonic machining of carbon fiber–reinforced plastic composites: effects of ultrasonic frequency. Int J Adv Manuf Technol 104, 3759–3772 (2019). https://doi.org/10.1007/s00170-019-04084-4

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