Zhao Jinghe, Wang Lulu, Jiang Bo, Pei Yongchen, Lu Huiqi
School of Mechanical Engineering, Changchun Guanghua University, Changchun 130033, China.
School of Mechanical and Aerospace Engineering, Jilin University, Changchun 130025, China.
Sensors (Basel). 2023 Jul 16;23(14):6444. doi: 10.3390/s23146444.
Ultrasonic-assisted inner diameter machining is a slicing method for hard and brittle materials. During this process, the sawing force is the main factor affecting the workpiece surface quality and tool life. Therefore, based on indentation fracture mechanics, a theoretical model of the cutting force of an ultrasound-assisted inner diameter saw is established in this paper for surface quality improvement. The cutting experiment was carried out with alumina ceramics (99%) as an exemplar of hard and brittle material. A six-axis force sensor was used to measure the sawing force in the experiment. The correctness of the theoretical model was verified by comparing the theoretical modeling with the actual cutting force, and the influence of machining parameters on the normal sawing force was evaluated. The experimental results showed that the ultrasonic-assisted cutting force model based on the six-axis force sensor proposed in this paper was more accurate. Compared with the regular tetrahedral abrasive model, the mean value and variance of the proposed model's force prediction error were reduced by 5.08% and 2.56%. Furthermore, by using the proposed model, the sawing processing parameters could be updated to improve the slice surface quality from a roughness Sa value of 1.534 µm to 1.129 µm. The proposed model provides guidance for the selection of process parameters and can improve processing efficiency and quality in subsequent real-world production.
超声辅助内径加工是一种针对硬脆材料的切片方法。在此过程中，锯切力是影响工件表面质量和刀具寿命的主要因素。因此，基于压痕断裂力学，本文建立了超声辅助内径锯切力的理论模型以提高表面质量。以99%的氧化铝陶瓷作为硬脆材料的示例进行了切割实验。实验中使用六轴力传感器测量锯切力。通过将理论建模与实际切削力进行比较，验证了理论模型的正确性，并评估了加工参数对法向锯切力的影响。实验结果表明，本文提出的基于六轴力传感器的超声辅助切削力模型更为准确。与常规四面体磨料模型相比，该模型力预测误差的平均值和方差分别降低了5.08%和2.56%。此外，使用该模型可以更新锯切加工参数，将切片表面粗糙度Sa值从1.534 µm提高到1.129 µm。该模型为工艺参数的选择提供了指导，能够在后续实际生产中提高加工效率和质量。
