Publicação
Development and manufacturing of a device for ultrasonic assisted milling
| Resumo: | Machinability, along with all its involved aspects, is the most crucial machining cost-determining parameter. Its optimization is, however, fundamentally limited by the existing technology. To transcend such limitations, new alternative technologies arise, as is the case with Ultrasonic Assisted Machining (UAM). Therefore, the present thesis aims to reimagine a conventional milling tool holder to allow for the application of an ultrasonic vibration system, seeking to increase machining efficiency. Chapter 1 serves as an introduction to the study, providing a brief overview of the project and its main objectives. General considerations and basic concepts of the machining technology are addressed. Chapter 2 is dedicated to a comprehensive overview of the ultrasonic machining technology. Initial developments of ultrasonics applied to distinct machining operations are briefly mentioned. However, ultrasonic assisted machining is the main addressed technique, with the milling process being the primary point of focus. The influence of the technology in key machining parameters is explored, as well as its underlying principles and general considerations, such as frequency, amplitude, and resonance. Additionally, a definition of different types of ultrasonic assisted machining systems and a comprehensive kinematic analysis are also provided. Chapter 3, the core of the document, describes the complete development of the ultrasonic assisted milling system. An existing system is analyzed and, through reverse engineering, its corresponding issues and efficiency-impeding factors are identified. Solutions for these limitations are proposed, and consequently, a complete redesign of the system is established, aiming for a more compact and functional design. Every aspect, from part design and optimization to production and consequent assembly, is addressed, recurring to an intensive FEA analysis to validate the proposed updated system. Three different studies are conducted: eigenfrequency determination, impedance curve plotting, and thermal expansion prediction for a shrink-fit type of tool fixation. Finally, in Chapter 4, conclusions are drawn regarding the optimized system and its applications in the machining industry. The chapter includes a comprehensive overview of the project and suggestions for future improvements, providing valuable insights into the practical implications of this research and its potential for advancing the field of machining. Overall, the developed system yields a significant contribution to the machining field, presenting an innovative approach to ultrasonic assisted machining, having the potential to reduce cutting forces, improve surface finish and reduce tool wear, ultimately leading to cost savings and increased productivity. |
|---|---|
| Autores principais: | Martins, Henrique Lima |
| Assunto: | Frequency Machinability Optimization Ultrasonics Vibration Frequência Maquinabilidade Otimização Ultrassons Vibração Engenharia e Tecnologia::Engenharia Mecânica |
| Ano: | 2023 |
| País: | Portugal |
| Tipo de documento: | dissertação de mestrado |
| Tipo de acesso: | acesso aberto |
| Instituição associada: | Universidade do Minho |
| Idioma: | inglês |
| Origem: | RepositóriUM - Universidade do Minho |
| Resumo: | Machinability, along with all its involved aspects, is the most crucial machining cost-determining parameter. Its optimization is, however, fundamentally limited by the existing technology. To transcend such limitations, new alternative technologies arise, as is the case with Ultrasonic Assisted Machining (UAM). Therefore, the present thesis aims to reimagine a conventional milling tool holder to allow for the application of an ultrasonic vibration system, seeking to increase machining efficiency. Chapter 1 serves as an introduction to the study, providing a brief overview of the project and its main objectives. General considerations and basic concepts of the machining technology are addressed. Chapter 2 is dedicated to a comprehensive overview of the ultrasonic machining technology. Initial developments of ultrasonics applied to distinct machining operations are briefly mentioned. However, ultrasonic assisted machining is the main addressed technique, with the milling process being the primary point of focus. The influence of the technology in key machining parameters is explored, as well as its underlying principles and general considerations, such as frequency, amplitude, and resonance. Additionally, a definition of different types of ultrasonic assisted machining systems and a comprehensive kinematic analysis are also provided. Chapter 3, the core of the document, describes the complete development of the ultrasonic assisted milling system. An existing system is analyzed and, through reverse engineering, its corresponding issues and efficiency-impeding factors are identified. Solutions for these limitations are proposed, and consequently, a complete redesign of the system is established, aiming for a more compact and functional design. Every aspect, from part design and optimization to production and consequent assembly, is addressed, recurring to an intensive FEA analysis to validate the proposed updated system. Three different studies are conducted: eigenfrequency determination, impedance curve plotting, and thermal expansion prediction for a shrink-fit type of tool fixation. Finally, in Chapter 4, conclusions are drawn regarding the optimized system and its applications in the machining industry. The chapter includes a comprehensive overview of the project and suggestions for future improvements, providing valuable insights into the practical implications of this research and its potential for advancing the field of machining. Overall, the developed system yields a significant contribution to the machining field, presenting an innovative approach to ultrasonic assisted machining, having the potential to reduce cutting forces, improve surface finish and reduce tool wear, ultimately leading to cost savings and increased productivity. |
|---|