Abstract
This contribution presents a novel design approach for vibration assisted machining (VAM). A lot of research has already been done regarding the influence of superimposed vibrations during a milling process, but there is almost no information about how to design a VAM tool where the tool is actually rotating. The proposed system consists of a piezoelectric actuator for vibration excitation, an inductive contactless energy transfer system and an electronic circuit for powering the actuated tool. The main benefit of transferring the required power without mechanical contact is that the maximum spindle speed is no longer restricted by friction of slip rings. A detailed model is shown that enables for preliminary estimation of the system’s response to different excitation signals. Experimental data are provided to validate the model. Finally, some parts are shown that have been manufactured using the contactlessly actuated milling tool.
Highlights
Conventional vibration assisted machining (VAM) comprising drilling, milling, turning, cutting and grinding with small stroke superimposed vibrations on either the cutting tool or the workpiece aims to improve the fabrication processes
Microstructured surfaces could be beneficial from a tribological point of view [6,7]
Only the active power needs to be transferred as normally the inductive parts are compensated by capacitances. This is the case in ultrasonic VAM where contactless energy transfer is more common
Summary
Conventional vibration assisted machining (VAM) comprising drilling, milling, turning, cutting and grinding with small stroke superimposed vibrations on either the cutting tool or the workpiece aims to improve the fabrication processes. In VAM, when enhancing the machining process enhancement, e.g., cutting force and tool wear reduction or chip breakage improvement, is the focus, the piezoelectric actuators are driven at a single excitation frequency in resonance operation mode. Research in VAT is based on non-resonant piezoelectric actuation to allow for nearly arbitrary periodic vibration forms of the tool tip. Transferring the required power contactlessly could be beneficial since it allows for higher cutting speeds and shorter manufacturing times In this contribution, a design procedure will be shown for a contactlessly powered 1D-actuator mounted inside the rotating tool for exciting an axial vibration during the milling process. An experimental setup will be shown that was both used to validate the model and to be able to manufacture parts with a textured surface
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