Proceedings of the
9th International Conference of Asian Society for Precision Engineering and Nanotechnology (ASPEN2022)
15 – 18 November 2022, Singapore
doi:10.3850/978-981-18-6021-8_OR-07-0157
Parametric model and optimization conditions in high-frequency ultrasonic vibration-assisted turning of optical spherical convex mold
1State Key Laboratory of Ultra-Precision Machining Technology, Department of Industrial and Systems Engineering,
2The Hong Kong Polytechnic University, Kowloon, Hong Kong, China
ABSTRACT
Ultrasonic vibration-assisted cutting improves the machinability of difficult-to-cut materials to achieve nanoscale superfinished surfaces. This work focused on the parametric model and optimization conditions in high-frequency ultrasonic vibration-assisted turning of optical spherical convex mold, including tool radius r, cutting speed v, feed rate f, vibration amplitude A, slope angle S. Firstly, the parametric model for predicting surface roughness based on response surface method (RSM) was established. The adequacy of parametric model was proved by analysis of variance. Secondly, the effects of cutting conditions and their interaction on surface roughness were analyzed. Experimental results indicated that the influence degrees of cutting conditions on surface roughness were inconsistent, which the percentage contribution of r, v, f, A, and S to the surface roughness were 14.44%, 3.51%, 34.41%, 2.64% and 27.75%, respectively. Higher tool radius and vibration amplitude decrease surface roughness while the elevated of cutting speed, feed rate and slope angle increased the surface roughness. Based the parameter optimization as the solution of desirability function, the most ideal cutting conditions with the desirability value of 0.717 was r=1 mm, v=2.99 m/min, f=6.7 µm/rev, A=2.4µm, S=0-15° achieved the goals of surface roughness and material removal rate.
Keywords: Ultrasonic-assisted vibration turning, Convex mold, Parametric model, Parameter optimization, Ultra-precision machining
1State Key Laboratory of Ultra-Precision Machining Technology, Department of Industrial and Systems Engineering,
2The Hong Kong Polytechnic University, Kowloon, Hong Kong, China
ABSTRACT
Ultrasonic vibration-assisted cutting improves the machinability of difficult-to-cut materials to achieve nanoscale superfinished surfaces. This work focused on the parametric model and optimization conditions in high-frequency ultrasonic vibration-assisted turning of optical spherical convex mold, including tool radius r, cutting speed v, feed rate f, vibration amplitude A, slope angle S. Firstly, the parametric model for predicting surface roughness based on response surface method (RSM) was established. The adequacy of parametric model was proved by analysis of variance. Secondly, the effects of cutting conditions and their interaction on surface roughness were analyzed. Experimental results indicated that the influence degrees of cutting conditions on surface roughness were inconsistent, which the percentage contribution of r, v, f, A, and S to the surface roughness were 14.44%, 3.51%, 34.41%, 2.64% and 27.75%, respectively. Higher tool radius and vibration amplitude decrease surface roughness while the elevated of cutting speed, feed rate and slope angle increased the surface roughness. Based the parameter optimization as the solution of desirability function, the most ideal cutting conditions with the desirability value of 0.717 was r=1 mm, v=2.99 m/min, f=6.7 µm/rev, A=2.4µm, S=0-15° achieved the goals of surface roughness and material removal rate.
Keywords: Ultrasonic-assisted vibration turning, Convex mold, Parametric model, Parameter optimization, Ultra-precision machining
