Title: Controlled vibration amplitude in ultrasonic assisted grinding using FRF guided cutting frequency

Authors: Mohamed M. Mansour; Hassan El-Hofy; Jiwang Yan; Ibrahem Maher; Mohamed G.A. Nassef; Wael Mahmoud Khaireldien

Addresses: Department of Industrial and Manufacturing Engineering (IME), Egypt-Japan University of Science and Technology (E-JUST), Alexandria 21934, Egypt; Department of Production Engineering and Mechanical Design, Faculty of Engineering, Menoufia University, Menoufia 32515, Egypt ' Department of Production Engineering, Faculty of Engineering, Alexandria University, Alexandria 21544, Egypt ' Department of Mechanical Engineering, Faculty of Science and Technology, Keio University, Hiyoshi 3-14-1, Kohoku-ku, Yokohama, 223-8522, Japan ' Department of Industrial and Manufacturing Engineering (IME), Egypt-Japan University of Science and Technology (E-JUST), Alexandria 21934, Egypt; Department of Mechanical Engineering, Faculty of Engineering, Kafrelsheikh University, Kafrelsheikh 33516, Egypt ' Department of Industrial and Manufacturing Engineering (IME), Egypt-Japan University of Science and Technology (E-JUST), Alexandria 21934, Egypt; Department of Production Engineering, Faculty of Engineering, Alexandria University, Alexandria 21544, Egypt ' Department of Industrial and Manufacturing Engineering (IME), Egypt-Japan University of Science and Technology (E-JUST), Alexandria 21934, Egypt; Department of Mechanical Engineering, Faculty of Engineering, Assiut University, Assiut 71516, Egypt

Abstract: In ultrasonic-assisted machining, vibration amplitudes can be controlled at the resonant frequency by altering the ultrasonic power. However, the availability of amplitude controlled ultrasonic power is constrained to limited types of machine tools. The present study introduces a novel idea for generating identified vibration amplitudes for a diamond-grinding tool by adjusting the ultrasonic frequency in the range from 20 kHz to 30 kHz. For this purpose, experimental model analysis (EMA) is carried out on five different diamond-grinding tools to obtain their frequency response function (FRF) curves. The vibration amplitude is measured using a dial indicator and eddy current sensor methods. Further analysis is conducted using 3D laser microscope after machining to decide the proper measurement method. It is found that various amplitudes can be successfully accurately reached from an individual cutting tool by altering the input ultrasonic frequency according to the generated FRF curve of the tool.

Keywords: ultrasonic-assisted grinding; experimental modal analysis; EMA; frequency response function; FRF; vibration amplitude.

DOI: 10.1504/IJMMM.2023.136033

International Journal of Machining and Machinability of Materials, 2023 Vol.25 No.3/4, pp.408 - 431

Received: 26 Jun 2023
Accepted: 25 Aug 2023
Published online: 12 Jan 2024 *

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