Compared to conventional machining (CM), ultrasonic vibration-assisted machining (UVAM) with high-frequency and small-amplitude has exhibited good cutting performances for advanced materials. In recent years, advances in ultrasonic generator, ultrasonic transducer, and horn structures have led to the rapid progress in the development of UVAM. Following this trend, numerous new design requirements and theoretical concepts have been proposed and studied successively, however, very few studies have been conducted from a comprehensive perspective. To address this gap in the literature and understanding the development trend of UVAM, a critical overview of UVAM is presented in this study, covering different vibration-assisted machining styles, device architectures, and theoretical analysis. This overview covers the evolution of typical hardware systems used to achieve vibratory motions from the one-dimensional UVAM to three-dimensional UVAM, the discussion of cutting characteristics with periodic separation between the tools and workpiece and the analysis of processing properties. Challenges for UVAM include ultrasonic vibration systems with high power, large amplitude, and high efficiency, as well as theoretical research on the dynamics and cutting characteristics of UVAM. Consequently, based on the current limitations and challenges, device improvement and theoretical breakthrough play a significant role in future research on UVAM.

Review of ultrasonic vibration-assisted machining in advanced materials

Advances in laser assisted machining of hard and brittle materials

Variation in the sulfate attack resistance of iron rich-phosphoaluminate cement with mineral admixtures subjected to a Na2SO4 solution

Float glass, which is a hard and brittle material, is generally machined and drilled using rotary ultrasonic machining and conventional drilling to create products such as solar panels, metrologica...

Multi-shaped tool wear study during rotary ultrasonic drilling and conventional drilling for amorphous solid:

Machining of ceramic materials: a state-of-the-art review

Rotary ultrasonic machining(RUM) as a precise and efficient processing method for hard and brittle materials can be used for significantly improving processing efficiency, reducing the cutting force and cutting heat, improving the surface quality. Development of high performance RUM machine tools and equipments has been caused on widespread attention from the worldwide scholars. In this paper, the development of the RUM machine tools has been reviewed about the accessory RUM head and load matching system.

Review on the Development of the Accessory Rotary Ultrasonic Machining Tools

A novel air bearing workbench used in rotary ultrasonic drilling of advanced ceramics was designed to constantly and sensitively control the cutting force. Compared with traditional feed systems, the novel air bearing workbench features an aerostatic guide and a pneumatic actuator, so that it only overcomes the air damping when the cutting force is balanced. Thus, it can sensitively and constantly control the cutting force for rotary ultrasonic drilling of advanced ceramics. The aerostatic guide, which determines the eccentric bearing capacity and stiffness of the workbench, is the most important part. The forces applied on the aerostatic guide faces were analyzed to calculate the bearing capacity and stiffness of the workbench using varying gas film thicknesses with finite element method (FEM). Based on the result of the analysis, the best gas film thickness of the aerostatic guide was designed to be 30 μm. The real eccentric bearing capacity and stiffness of the workbench were measured. The error between experimental results and the FEM results was within 12%.

Design of a Novel Air Bearing Workbench for Rotary Ultrasonic Drilling of Advanced Ceramics

A novel adaptive force control table for rotary ultrasonic machine tool was developed for processing micro holes. The adaptive force control table, a mechanical balancing device by which the load can be adaptively adjusted without numerical control was adopted as an attachment in an ultrasonic machine tool. To verify the performance, micro holes were drilled on SiC workpiece. The drilling force, tool wear and profiles of these machined micro holes were investigated. According to the experimental results, it is confirmed that the newly developed table attached on the ultrasonic machine tool is an economical and efficient approach for machining micro holes on hard and brittle materials.

Study on a Novel Adaptive Force Control Table Employed for Rotary Ultrasonic Drilling

It is difficult to calculate with finite element method or actually measure the temperature distribution of the ceramic sintering at irregular sintering curve. Trained by the temperature distribution data of ceramic sintering analyzed with ANSYS under linear sintering curves including different slopes, the neural network can be used to simulate that under irregular sintering curve at certain precision, so the temperature evolution of the ceramic hot geometry centroidal point (HGCP) can be fast obtained by the result simulated with the trained neural network. This research sets up series-parallel BP neural network model with MATLAB. The ceramic sintering date analyzed with ANSYS under linear sintering curves with ten different slopes is used as training sample of the neural network which is tested by the sample under non-linear sintering curve. The result indicates that the BP neural network is feasible for simulating temperature distribution of the ceramic sintering.

Simulation of Temperature Distribution during Ceramic Sintering Based on BP Neural Network Technology

As a zero-emission mode of transportation, an increasing number of Electric Vehicles (EV) have come into use in our daily lives. The EV charging station is an important component of the Smart Grid which is now facing the challenges of big data. This paper presents a data compression and reconstruction method based on the technique of Principal Component Analysis (PCA). The data reconstruction error Normalized Absolute Percent Error (NAPE) is taken into consideration to balance the compression ratio and data reconstruction quality. By using the simulated data, the effectiveness of data compression and reconstruction for EV charging stations are verified.

Data Compression and Reconstruction for EV Charging Stations Based on Principal Component Analysis

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