• Transactions of the Korean Society for Noise and Vibration Engineering
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• v.22 no.9
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• pp.903-909
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• 2012

In elliptical vibration cutting(EVC) where the cutting tool traces a micro-scale 2-dimensional elliptical trajectory, the kinematical and vibrational characteristics of the EVC device greatly affect cutting performance. In this study, kinematical and vibrational characteristics of an EVC device constructed with two orthogonally-arranged stacked piezoelectric actuators were investigated both analytically and experimentally. The step voltage was applied to the orthogonal EVC device and the associated displacements of the cutting tool were measured to assess kinematical characteristics of the orthogonal EVC device. To investigate the vibrational characteristic of the orthogonal EVC, sinusoidal voltage was applied to the EVC device and the resulting displacements were measured. It was found from experiments that coupling of displacements in the thrust and cutting directions and the tilt of the major axis of the elliptical trajectory exists. In addition, as the excitation frequency is in vicinity of resonant frequencies the distortion in the shape of the elliptical trajectory becomes greater and change in the rotation direction occurs. To correct the shape distortion of the elliptical trajectory, the shape correcting procedure developed for the parallel EVC device was applied for the orthogonal EVC device and it was shown that the shape correcting method successfully corrects distortion.

• Journal of the Korean Society for Precision Engineering
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• v.25 no.3
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• pp.56-62
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• 2008

The biocompatibility and the fatigue strength of Co-Cr-Mo alloy are excellent, so it is used well for the material of artificial joints. The head of artificial joint needs mirror surface for reduction of abrasive resistance. Mirror finishing of Co-Cr-Mo alloy with geometrically defined single crystal diamond cutting tools is handicapped by micro chipping of tool edge. In general, it is said that the micro chipping of diamond tool is caused by work hardening of Co-Cr-Mo alloy for the cut. In the present research, mirror finishing of Co-Cr-Mo alloy by applying ultrasonic elliptical vibration cutting was carried out. The experimental results show that the micro chipping of diamond tool was suppressed and the tool wear was remarkably reduced as compared with the ordinary diamond cutting without elliptical vibration motion. It was confirmed that the good mirror surface of maximum surface roughness of 25 nmP-V was obtained for the cutting length of about 14 m. It is expected that mirror finishing of Co-Cr-Mo alloy can be achieved by applying ultrasonic elliptical vibration cutting practically.

• Proceedings of the Korean Society of Precision Engineering Conference
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• 2005.06a
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• pp.625-628
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• 2005

For precise micro-grooving and surface machining, ultrasonic cyclic elliptical cutting is proposed using two parallel piezoelectric actuators. The piezoelectric actuators are energized by sinusoidal voltages of varying phase which is essenstial to generating elliptical cutting. Experimental setup is composed of ultrasonic motor, single crystal diamond cutting tool, and precise motorized xyz stage. It is confirmed experimentally that the cutting performance, in terms of the cutting force, the burr formation, and the discontinuous chip formation is improved remarkably by applying ultrasonic elliptical vibration cutting.

• Proceedings of the Korean Society of Precision Engineering Conference
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• 2012.05a
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• pp.169-170
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• 2012

• International Journal of Precision Engineering and Manufacturing
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• v.2 no.3
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• pp.41-46
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• 2001

This paper discusses the feasibility of improving micro-machining accuracy by using two-dimensional(2-D) vibration cutting. Vibration cutting is generated by two piezo actuators arranged orthogonally : one is actuated by a sine curve voltage input, and the other is actuated by a phase-shifted sine curve voltage. A tool attached to the vibrator oscillates in a 2-D elliptical motion, depending on the frequencies, amplitudes, and the phase shifts of two input signals and the workpiece feedrate. Along the elliptical tool locus, cutting is done in the lower part, and non-cutting is done in the upper part. By this way a unique feature of 2-D vibration cutting, that is, air lubrication between a tool and chips, is caused. Another unique feature of 2-D vibration cutting was experimentally verified, that is, some negative thrust force occurs as the direction of chip movement on a tool rake face is reversed. Those features not only help chips flow smoothly and continuously but also reduce cutting force, which results in a higher quality machined surface. Through tool path simulations and experiments under several micro-machining conditions, the 2-D vibration cutting, compared to conventional cutting, was found to result in a great decrease in the cutting force, a much smoother surface, and much less burr.

• Journal of the Korean Society for Precision Engineering
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• v.26 no.6
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• pp.42-49
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• 2009

The optical elements made of plastics are normally produced by mass production such as injection molding with use of precision dies and molds. It costs to prepare the dies and molds, and it is only justified to prepare such expensive dies and molds when the parts are massively produced. On the other hand, it is too expensive and inefficient when precision plastic parts are needed only in small quantities, such as a case of trial manufacturing of new products. An ultra-precision diamond cutting is one of promising processes to produce the precision plastic parts in such cases. But it is commonly believed that an ultra-precision cutting of plastics for optical components is very difficult, because they are thermo-plastic material. In the present research, an ultra-precision diamond cutting of polycarbonate (PC), that is one of typical optical materials, was tried by using elliptical vibration cutting method. It is experimentally proved that good optical surfaces were obtained by using elliptical vibration cutting in cases of grooving and flat surfaces. The maximum surface roughness of less than 60 nm in peak to valley value is acquired.

• Journal of the Korean Society of Manufacturing Process Engineers
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• v.13 no.1
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• pp.59-65
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• 2014

To obtain an elliptical trajectory at the cutting edge during elliptical vibration cutting, sinusoidal voltage excitations of two piezoelectric actuators have commonly been used. In this study, PWM excitation, which is relatively simple to generate, was employed and its characteristics were investigated. In experimental and analytical analyses, we found that for PWM excitation, the integer-multiple frequencies of the excitation voltage distorted the shape of the elliptical trajectory, whereas at a duty ratio(DR) of 50%, the distortion of the elliptical trajectory was minimized due to disappearance of the first overtone. When the magnitude of the maximum excitation voltage was maintained at the same level for both PWM and sinusoidal excitation, PWM (DR=50%) excitation produced a greater vibration amplitude than sinusoidal excitation but resulted in more rapid saturation of a high-frequency power amplifier.

• Proceedings of the Korean Society of Precision Engineering Conference
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• 2006.10a
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• pp.109-110
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• 2006

• Journal of the Korean Society for Precision Engineering
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• v.25 no.11
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• pp.45-51
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• 2008

Successive micro-scale V-grooves and a grid of pyramids were machined by elliptical vibration tufting (EVC) to investigate feasibility of using EVC as an alternative method of creating micro-molds to photo-lithography and electroforming, which have been commonly employed. An elliptical vibration grooving machine was developed which consists of two orthogonally-arranged piezoelectric actuators, a diamond cutting tool, and a motorized xyz stage. The micro-scale features were machined on materials of copper, duralumin, nickel, and hastelloy and it was found that EVC significantly reduces cutting resistance and prohibits generation of side burrs and rollover burrs, thus resulting in improving machining qualify of micro-molds in ail experimented workpiece materials.

• Journal of the Korean Society for Precision Engineering
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• v.16 no.3 s.96
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• pp.72-77
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• 1999

This paper presents 2-dimensional vibration cutting increases dynamic stiffness of tool support and improves the quality of machined surface in micro-machining. 2-dimensional vibration cutting is generated by two piezo actuators arranged orthogonally. A sine-type voltage is input to one actuator and a phase-shifted sine-type voltage is input the other. Then the vibration device actuates the tool in a 2-D elliptical motion with pulsed cutting force. It is a characteristic of 2-D vibration cutting that some negative thrust force occurs as the direction of friction on a tool rake surface is reversed. It helps not only chip flow smoothly and continuously but also cutting force be reduced. The quality of machined surface by 2-D vibration cutting depends on such parameters as vibration amplitude, frequency, cutting speed, depth of cut, etc. Compared to conventional cutting through tool path simulation and experiments under several conditions, the 2-D vibration cutting is verified to bring forth a great decrease of cutting forces, much better surface roughness and moreover much less burr.