Diamond Turning of a Metal Matrix Composite with Ultrasonic Vibrations

ABSTRACT

The objectives of this study are to develop an ultrasonic vibration device, investigate diamond turning of an aluminium-based metal matrix composite (MMC) reinforced with SiC particles with ultrasonic vibrations applied to the cutting tool, and evaluate effects of cutting parameters on the surface finish of turned MMC samples. A low-cost, small-size vibration device was designed to mount a piezoelectric transducer and cutting tool onto a low-end CNC machine. Cutting experiments were carried out using a fractional factorial design to investigate the effects of cutting parameters. The experimental results show that surface roughness of the MMC samples cut with ultrasonic vibrations is better than that of the MMC sample cut without ultrasonic vibrations. Depth of cut and cutting speed also affect the surface finish significantly. A light dispersion phenomenon, which is not reported in other articles, is observed and explained.

Key Words:

• Cost
• Cutting speed
• Depth of cut
• Design
• Diamond turning
• Experiments
• Fractional factorial design
• Light dispersion
• Metal matrix composite
• Piezoelectric actuator
• Pitch
• Surface roughness
• Ultrasonic vibration
• Vibration device
• Vibration frequency

ACKNOWLEDGMENTS

The authors wish to express their appreciation for the assistance provided by Ms. K. F. Lee and Ms. Pamela J. L. Loh of Mechatronics and Control Lab, Ms. Esther H. J. Tan and Mr. W. L. Koh of CNC Lab, and Ms. Sandy P. N. Yeong of Materials Lab, in the School of Mechanical and Production Engineering, Nanyang Technological University. This research is supported by AcRF RG31/99 of Nanyang Technological University.