• International Journal of Precision Engineering and Manufacturing-Green Technology
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• v.5 no.5
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• pp.571-581
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• 2018

In the present study, monitoring of elliptical vibration cutting process by utilizing internal data in the ultrasonic elliptical vibration device without external sensors such as a dynamometer and displacement sensor is investigated. The internal data utilized here is the change of excitation frequency, i.e. resonant frequency of the device, voltages applied to the piezoelectric actuators composing the device, and electric currents flowing through the actuators. These internal data change automatically in the elliptical vibration control system in order to keep a constant elliptical vibration against the change of the cutting process. Correlativity between the process and the internal data is described by using a vibration model of ultrasonic elliptical vibration cutting and verified by several experiments, i.e. planing and mirror surface finishing of hardened die steel carried out with single crystalline diamond tools. As a result, it is proved that it is possible to estimate the elements of elliptical vibration cutting process, e.g. tool wear and machining load, which are important for stable cutting in such precision machining.

• Journal of the Korean Society of Manufacturing Process Engineers
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• v.5 no.3
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• pp.29-35
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• 2006

Various types of elliptical motions are generated by PZT mechanism which is composed of two parallel piezoelectric actuators. Elliptical vibration cutting(EVC) is obtained by attaching single crystal diamond cutting tool to the mechanism, and V-grooving for Brass and Aluminum is carried out by applying the EVC. It is experimentally observed that the cutting force in the process of the EVC reduces compared to the ordinary non-vibration cutting, which is due to the decrease of undeformed chip thickness and frictional force between the tool and chip. Ultrasonic elliptical vibration cutting(UEVC) suppresses burr formation and decreases cutting force still more, so UEVC makes it possible to enhance the shape accuracy of machined surface.

• Proceedings of the Korean Society of Precision Engineering Conference
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• 2007.06a
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• pp.11-12
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• 2007

• Journal of the Korean Society for Precision Engineering
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• v.28 no.7
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• pp.789-795
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• 2011

In elliptical vibration cutting (EVC), cutting performance is largely affected by the shape of an elliptical path of the cutting tool. In this study, two parallel piezoelectric actuators were used to make an elliptical vibration cutting device. When harmonic voltages of $90^{\circ}$ out-of-phase are supplied to the EVC device, creation of an ideal elliptical trajectory whose major and minor axes are parallel to the cutting and thrust directions is anticipated from a kinematic analysis of the EVC device, however, the paths we experimentally observed showed significant distortions in its shape ranging from skew to excessive elongation of the major axis of the ellipse. To compensate distortions, an analytical model describing the elliptical path of the cutting tool was developed and verified with experimental results, and based on the analytical model, the distorted elliptical paths created at 100 Hz, 1 kHz, and 16 kHz were corrected for skew and elongation.

• Journal of the Korean Society for Precision Engineering
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• v.22 no.12 s.177
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• pp.198-204
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• 2005

For precise micro V-grooving, ultrasonic elliptical vibration cutting (UEVC) is proposed using two parallel piezoelectric actuators, which are energized by sinusoidal voltages with a phase difference of 90 degrees. Experimental setup is composed of stacked PZT actuators, a single crystal diamond cutting tool, and a precision motorized xyz stage. It is found that the chip formed in the process of UEVC is discontinuous because of the periodic contacts and non-contacts occurring between the tool and workpiece. It is experimentally observed that the cutting force in the process of UEVC significantly reduces compared to the ordinary non-vibration cutting. In addition, the creation of burr during UEVC is significantly suppressed, which is attributable to the decrease in the specific cutting energy.

• Transactions of the Korean Society for Noise and Vibration Engineering
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• v.21 no.3
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• pp.258-263
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• 2011

The direction of the cutting tool plays a critical role in elliptical vibration cutting(EVC) where the cutting tool cuts workpiece in a trochoidal motion. In this study, EVC cutting device was developed using two parallel piezoelectric materials and it was observed that the rotation direction of the tool reverses as the EVC device undergoes resonance at which either flexural(cutting direction) or longitudinal( thrust direction) mode shapes occurs. To analytically explain reversal of the rotation direction, kinematic motion analysis of the tool was modified to incorporate amplification of the vibration amplitude and phase introduced by resonance. It successfully demonstrated, through Matlab simulation, reversal of the rotation direction of the cutting tool as the excitation frequency increases beyond resonance frequencies at which either flexural or longitudinal vibration occurs.

• Proceedings of the Korean Society of Precision Engineering Conference
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• 2004.10a
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• pp.34-37
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• 2004

In the present research, a ultra-precision diamond cutting of thermo-plastic materials, polycarbonate (PC) and cyclic olefin polymer (COC), is carried out by applying a method named ultrasonic elliptical vibration cutting developed by the authors. It is experimentally proved that good optical surfaces are obtained by applying the elliptical vibration cutting in cases of machining of flat surfaces and grooves as compared with the conventional diamond cutting. The maximum surface roughness in peak to valley value obtained is less than 60 nm and 20 nm for PC and ZEONEX, respectively.

• Transactions of the Korean Society for Noise and Vibration Engineering
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• v.21 no.12
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• pp.1185-1191
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• 2011

The kinematic characteristics of cutting device significantly affects cutting performance in 2-dimensional elliptical vibration cutting(EVC) where the cutting tool cuts workpiece, traversing a micro-scale elliptical trajectory in a trochoidal motion. In this study, kinematical characteristics of EVC device constructed with two parallel stacked piezoelectric actuators were analytically modeled and compared with the experimental results. The EVC device was subjected to step and low-frequency(0.1 Hz) sinusoidal inputs to reveal only its kinematical displacement characteristics. Hysteresis in the motion of the device was observed in the thrust direction and distinctive skew of the major axis of the elliptical trajectory of the cutting tool was also noticed. Discrepancy in the voltage-to-displacement characteristics of the piezoelectric actuators was found to largely contribute to the skew of the major axis of the elliptical trajectory of the cutting tool. Analytical kinematical model predicted the cutting direction displacement within 10 % error in magnitude with no phase error, but in estimating the thrust direction displacement, it showed a $27^{\circ}$ of phase-lag compared with the measured displacement with no magnitude error.

• Journal of the Korean Society for Precision Engineering
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• v.22 no.12 s.177
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• pp.190-197
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• 2005

For precise micro-grooving and surface machining, a mechanism for creating elliptical vibration cutting (EVC) motion is proposed which uses two parallel piezoelectric actuators. And based on its kinematical analysis, variations of EVC path are investigated as a function of dimensional changes in the mechanism, phase difference and amplitude of excitation sinusoidal voltages. Using the proposed PZT mechanism, various types of two dimensional EVC paths including one dimensional vibration cutting path along the cutting direction and thrust direction can be easily obtained by changing the phase lag, the amplitude of the piezoelectric actuators, and the dimension of the mechanism.

• Journal of the Korean Society for Precision Engineering
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• v.24 no.11
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• pp.52-58
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• 2007

A cutting device capable of generating various shapes of the cyclic elliptical trajectory of a cutting tool was proposed and micro v-grooving experiments were performed to investigate the characteristics of elliptical vibration cutting (EVC). The proposed cutting device is comprised of a pair of parallel piezoelectric actuators with which harmonic voltages of varying phase difference and magnitude are supplied, creating various shapes of the elliptical tool path. The attributes of the elliptical locus involving the direction of the axis of an ellipse, the rotational direction and amplitudes of a trajectory were fine-tuned for stable operation of the EVC. The EVC characteristics performed with brass and copper revealed reduction in the cutting resistance and suppression of burr formation, resulting in the enhancement of form accuracy of machined micro-features. While the effect of the EVC increases with the increase of excitation frequency and the amplitude, it is found that a change in the cutting force decreases as the amplitude of an elliptical locus increases.