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Original Article

Proc IMechE Part B:


J Engineering Manufacture
1–11
A novel three-dimensional elliptical Ó IMechE 2018
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DOI: 10.1177/0954405417752507

freedom and constraint topologies journals.sagepub.com/home/pib

theory

Sheng Lin , Xi Kong, Chun Wang, Yun Zhai and Liang Yang

Abstract
Aiming at the issue of the lack of the design theory for the three-dimensional elliptical vibration cutting device, a compli-
ant mechanism with two rotations and one translation is synthesized based on the theory of freedom and constraint
topologies. And a three-dimensional elliptical vibration cutting device is proposed on the basis of the compliant mechan-
ism. The relationship between the critical speed and the length of the tool bar is analyzed. Simulation is conducted to
analyze the influence of parameters on the output ellipse. Experiments are conducted to verify the validity of the ellipti-
cal vibration cutting device. The relationship between the roughness and the cutting speed is obtained. Experiments with
different driving frequencies are conducted without the change of other parameters. Results show that the proposed
compliant mechanism is feasible for the elliptical vibration cutting device. Compared with the common cutting, the new
elliptical vibration cutting device has a better performance in the processing effect. This provides an important reference
for design of the elliptical vibration cutting device.

Keywords
Parallel, compliant mechanism, elliptical vibration cutting device, freedom and constraint topologies theory, finite element
method

Date received: 23 August 2016; accepted: 5 November 2017

Introduction analytical model, the distortions in the elliptical trajec-


tories created at various frequencies were corrected for
Processing quality can be improved by vibration cutting tilt and aspect ratio by changing the phase and relative
because the cutting force, the cutting heat, and the tool magnitude of the sinusoidal excitation voltages.
wear are greatly reduced. As an important branch of Nosouhi et al.6 presented a novel analytical model for
vibration cutting, three-dimensional elliptical vibration prediction of forces in elliptical vibration-assisted turn-
cutting (EVC) has drawn extensive attention in recent ing using a dynamic friction model. The cutting forces
years. However, the types of the three-dimensional are determined by incorporating the friction forces cal-
EVC device cannot meet the growing requirements culated from the model. Amini et al.7 designed an ellip-
because of the lack of the design theory. tical ultrasonic–assisted turning tool, in which the
Shamoto et al.1,2 developed a three-dimensional
longitudinal and bending vibration modes have
EVC device on the basis of the two-dimensional EVC.
the minimum resonance frequency difference, so that
Shamoto and Suzuki3 also demonstrated that EVC con-
the resonance of both the vibration modes can be
siderably improves cutting performance in terms of tool
life, surface quality, and applicability to free-form sur-
face machining and micromachining. Jung et al.4 clari-
fied the mechanism of undesirable vibration observed School of Mechanical Engineering, Dalian Jiaotong University, Dalian,
during high-efficiency EVC. And the mechanism is China
investigated by analyzing the finished surfaces and the
Corresponding author:
undesirable vibrations superimposed on the elliptical Sheng Lin, School of Mechanical Engineering, Dalian Jiaotong University,
vibration. Loh and Kim5 developed an analytical model No. 794 Huanghe Road, Dalian Shahekou, Dalian 116028, China.
describing the elliptical path of the tool. Based on the Email: linsheng138@163.com
2 Proc IMechE Part B: J Engineering Manufacture 00(0)

achieved in a definite frequency. Zhou et al.8 proposed where T denotes a 6 3 1 twist vector, c denotes a 1 3 3
a double-frequency EVC apparatus, which combined location vector, w denotes a 1 3 3 orientation vector,
fast tool servo and EVC. Bai et al.9 presented the pre- and p denotes a scalar pitch value.
dicted model of orthogonal cutting force, which was The wrench constraint of a compliant element in a
helpful to explain the phenomena that EVC could compliant mechanism can be defined as
reduce the cutting force, lower cutting temperature, and
improve the surface integrity. Yin et al.10 developed a W = ½ f (r 3 f ) + q f T = ½ f tT ð2Þ
novel single-driven ultrasonic EVC device with a
where W represents the 6 3 1 wrench vector, r denotes a
complex-beam horn. Compared to conventional cut-
1 3 3 location vector, f denotes a 1 3 3 orientation vec-
ting, the cutting force and surface roughness can be
tor, and q denotes a scalar constant.
reduced with the device. Lu and colleagues11,12 designed
A twist is complementary to a wrench if the recipro-
an EVC device with parallel compliant mechanism. The
cal product of a twist and a wrench is equal to zero.
structure is convenient to process, and the driving force
The equation can be expressed as15
is controlled under a lower value. Li et al.13 and Lin et
al.14 propose a non-resonant three-dimensional EVC W8T=0 ð3Þ
equipment to achieve both a high surface quality and
complex surface shape. Although researchers have Equation (3) can be simplified to the following
developed a variety of three-dimensional EVC device, equation
there is no system theory applied to design of the EVC
structure. Designer without years of experience cannot p + q = d  tan u ð4Þ
generate a possible design that would satisfy a given where d is the shortest distance between the twist and
motion requirement. Hopkins and colleagues15–17 pre- wrench lines, and u is the skew angle between the twist
sented the method of the freedom and constraint com- and wrench lines, as shown in Figure 1.
plement topology for design of compliant mechanism The above derivation is the basis of FACT theory.
with complex motion. This method embodies all possi- And all the freedom and constraint space can be
ble design solutions. obtained from equation (4). FACT proposed all kinds
Any designer can synthesize a suitable the EVC of desired motions such as rotational and translational
device even without enough experience if the theory is degrees of freedom.15 Designer can select possible con-
applied for design of the EVC device successfully. And straints within the constraint space to obtain required
a large number of EVC devices with different perfor- kinematics. Two rotations and one translation are
mance can be synthesized. Application of the freedom required for our three-dimensional EVC device. The
and constraint topologies theory to the design of the case 3 in FACT theory consists of all systems that con-
EVC device is significant for the development of three- tain three non-redundant constraints like the third line
dimensional EVC. added to two intersecting lines, the third line added to
Based on the theory of freedom degree and con- two parallel lines, the third line added to two screw
straint topologies, we have developed a novel three- lines and so on.15 Among these types, type6 meets our
dimensional EVC device. The stiffness matrix of the requirements perfectly. Then the freedom and con-
three-dimensional EVC device is derived according to straint space case3 type6 is selected, which is shown in
screw theory. Finite element analysis is conducted to Figure 2.
verify the correctness of the matrix. Experiments are In the constraint space in Figure 2(b), two parallel
carried out to obtain the relationship between the constraints are chosen in one plane, and in the other
roughness and the cutting speed, and the change law of plane, a constraint that is perpendicular to the two con-
the surface roughness with the driving frequency is straints is chosen. The positions of the three constraints
acquired. And the feasibility of the freedom and con- are shown in Figure 3.
straint topologies (FACT) theory for the design of According to the constraints in Figure 3, the compli-
three-dimensional EVC device is verified by the result ant mechanism with three freedom degree is synthesized
of simulation and experiment.

Synthesis of the compliant mechanism


with two rotations and one translation
The freedom and constraint of a compliant mechanism
can be expressed as force and kinematic screw, respec-
tively, in screw theory. The freedom of a compliant
element in a compliant mechanism is defined as15

T = ½w (c 3 w) + pwT = ½w vT ð1Þ Figure 1. The relationship between a twist and a wrench.15
Lin et al. 3

Figure 2. Freedom and constraints spaces of case3 type6:


(a) freedom space and (b) constraint space.15

Figure 4. Parameters that define compliant mechanism.

½N(a)  denote location and orientation of compliant ele-


ment, respectively
 
(a) 0 0 0 n1 n2 n3
½N R  =
n1 n2 n3 L 3 n1 L 3 n2 L 3 n3
ð7Þ
 
n1 n2 n3 0 0 0
Figure 3. Layout of the three constraints. ½N(a)  =
L 3 n1 L 3 n2 L 3 n3 n1 n2 n3
ð8Þ
in Figure 4. Two redundant constraints are added to
where 0 denotes 3 3 1 vector of zeros, n3 is oriented
increase stability of the mechanism and reduce thermal
along square compliant element, n2 is the direction per-
expansion errors. The stage is connected to the base by
pendicular to one-side plane of square constraint, n1 is
five compliant elements. The origin of the coordinate O-
determined by the right-hand rule, and the location vector
XYZ is set on the center of the surface. The direction ver-
L points from the origin of the coordinate system to the
tical to the stage upper surface is Z-axis, the direction
central point where compliant element attaches the stage.
with only one compliant element is Y-axis, and then X-
Then ½K 6 3 6 can be calculated as follows
axis is determined by the right-hand rule. To obtain the
2 3
relationship between input and output, local coordinate l l2
systems are established on the five compliant elements. 6 0 0 0 0 7
6 EI1 2EI1 7
The location vector Li (i = 1, 2, . . . , 5) points from the 6 l l2 7
6 0 0  0 0 7
origin O of the global coordinate system to the origin of 6 7
6 EI2 2EI2 7
the local coordinate system. The orthogonal unit vectors 6 l 7
6 0 0 0 0 0 7
n1 , n2 , and n3 point along the principle stiffness axes of 6 7
½Ke 6 3 6 = 6 GJ 7
the compliant elements. The elastic modulus and shear 6 l2
l 3 7
6 0  0 0 0 7
modulus of the compliant element are E and G, 6 2EI2 3EI2 7
6 7
respectively. 6 l2 l 3 7
6 0 0 0 0 7
The stiffness matrix links twist vectors to wrench 6 7
6 2EI1 3EI1 7
vectors rather than displacement vectors to force vec- 4 l 5
0 0 0 0 0
tors. The equation can be expressed as13 EA
ð9Þ
W = ½K T ð5Þ
where E denotes the modulus of elasticity, G denotes
where W denotes wrench vectors, T denotes twist vec- the shear modulus, I1 denotes the bending moment of
tors, ½K  denotes stiffness matrix, and ½K  is defined as inertia about the n1 axis, I2 denotes the bending
moment of inertia about the n2 axis, A denotes the
X
c
½K 6 3 6 = ½N(a) R ½Ke ½N(a) 1 ð6Þ cross-sectional area, J denotes the polar moment of
a=1 inertia, and l denotes the length.
For compliant element 1, the location vector is
where C is the number of compliant element, ½Ke  is the L = ½0, 0:02,  0:003, and the orthogonal unit vectors
stiffness matrix of compliant element, and ½N(a) R  and are n2 = ½0, 0, 1, n3 = ½0, 1, 0. For compliant element
4 Proc IMechE Part B: J Engineering Manufacture 00(0)

2, the location vector is L = ½0:02, 0:017,  0:015, and ANSYS software. In the finite element analysis, the
the orthogonal unit vectors are n2 = ½0, 0, 1, n3 = boundary conditions and assumptions should be con-
½1, 0, 0. For compliant element 3, L = ½0:02, sistent with equation (5). Since the working condition
0:017,  0:015, n2 = ½0, 0, 1, n3 = ½1, 0, 0. For the in reality is considered as a linear problem with small
compliant element 4, L = ½0:02,  0:017,  0:015, deformation, the stage is replaced by five constraint ele-
n2 = ½0, 0, 1, and n3 = ½1, 0, 0. For compliant ele- ment mpc184, and beam4 element is selected as the
ment 5, L = ½0:02, 0:017,  0:015, n2 = ½0, 0, 1, and compliant element. The finite element model is shown
n3 = ½1, 0, 0. The width of all the compliant elements in Figure 5(a). For the compliant elements, one node of
is 0.006 m, the length of compliant element 1 is beam4 is connected rigidly with one node of mpc184
0.025 m, and the length of compliant element 2,3,4,5 is element, and the other node of beam4 is constrained in
0.015 m. The width of the stage is 0.04 m, and the thick- all freedom degrees. The force along Z-axis, the torque
ness of the stage is 0.018 m. All the above parameters around Y-axis and X-axis are applied on the point O in
are substituted into equation (6), and the stiffness the middle of the rigid body, respectively. Figure 5(b)
matrix can be obtained as shows the rotation angle contour of the compliant
2 3
0 1:05e7 1:97e5 7:07e8 0 0
6 2:0e6 0 0 0 2:17e8 0 7
6 7
6 1:97e5 0 0 0 0 1:18e8 7
½KTW 6 3 6 = 6
6 6:69e4
7 ð10Þ
6 0 0 0 2:0e6 1:97e5 7 7
4 0 2:45e5 590:35 1:05e7 0 0 5
0 590:35 2:97e5 1:97e5 0 0

In order to verify the correctness of the stiffness mechanism around Y-axis if the torque around Y-axis
matrix in equation (10), simulation is carried out in the is acted on.

Figure 5. The displacement and rotation angle contour of the mechanism: (a) FEA model of the compliant mechanism, (b) rotation
angle around Y-axis, (c) rotation angle around X-axis, and (d) displacement along Z-axis.
Lin et al. 5

Table 1. Comparison between theory value and simulation value.

Direction of force and torque Force along Z-axis Torque around X-axis Torque around Y-axis

Value of force and torque 100 N 300 N 1Nm 8Nm 1Nm 8Nm
Displacement or rotation angle of theory value 8.5e–7 m 2.6e–6 m 2.1e–5 rad 1.7e–4 rad 1.2e–5 rad 9.1e–5 rad
Displacement or rotation angle of simulation value 8.9e–7 m 2.7e–5 m 2.5e–5 rad 2.0e–4 rad 1.1e–5 rad 8.7e–04 rad
Error % 4.5% 3.8% 19% 19% 8.3% 4.4%

Table 2. The first sixth-order vibration natural frequency.

Order number 1 2 3 4 5 6

Natural frequency (Hz) 3532.7 5814.6 6089.3 6584.9 11,608 12,178

The direction and loading position of the force and obtained if the phase difference, frequency, and ampli-
torque are constant, and the value of the force or tor- tude can be controlled as required.
que is gradually increased. The simulation and theory In Figure 7(b), the rotating angle of the stage around
value of displacement and rotation angle are shown in X- or Y-axis is denoted as u, and the length of the turn-
Table 1. The error of the theory value and simulation ing tool is denoted as L; then the displacement on the
value in Z-axis is minimum, which is less than 5%, and tip of turning tool can be calculated as follows
the rotation angle error around X-axis is maximum,
which is about 19%. dx(y) = u  L ð11Þ
The dynamic characteristic is the main performance Thus, the amplitude of the tip can be improved by
for the EVC device. To obtain the natural frequency increasing the length of the tool bar. For the separation
and main vibration mode, modal analysis is conducted type vibration cutting, the critical velocity can be
in ANSYS software. The element type is selected as improved by improving the amplitude of the tip. Then
solid45, and the aluminum alloy material is chosen. a wider range of spindle speeds can be adapted for the
The density of the material is 2700 kg/m3, the elastic vibration stage.
modulus is 73 GPa, and the Poisson ratio is 0.3. The If the actuators on point A and point B are driven,
first sixth-order modes of the mechanism are obtained. the new positions of points A, B, C, and D are changed
The first sixth-order vibration natural frequencies are to points A1, B1, C1, and D1. These positions are shown
shown in Table 2. We should avoid the resonance fre- in Figure 8. The displacements of A, B, C, and D along
quency region during processing. Z-axis are z1 , z2 , z3 , and z4 . Initial position coordinate
Figure 6 shows the vibration types of the compliant of the tip is denoted as P(x, y, z). The position coordi-
mechanism. The first-order vibration type of the com- nate after driving is denoted as P0 (x0 , y0 , z0 ). For the
pliant mechanism is translation in Z-axis. The second- angle change of the tool tip is small, the rotation angle
order vibration type is rotation around Y-axis. The u can be substituted with tan u. Then P0 (x0 , y0 , z0 ) can be
third-order vibration type is rotation around X-axis. deduced as follows
All the vibration types are consistent with the degree of  
8
freedom. > 0 z1  z2
>
> x = lOP
>
> 2l
>
<  OA 
z3  z4
Design of EVC device based on the parallel > y0 = lOP
>
> 2lOC
compliant mechanism >
> qffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffi
>
: z0 = 1(z + z 2 + z 3 + z 4 )
+ lop 2  x  y  lop
A novel EVC device is developed based on the above 4
parallel compliant mechanism. The turning tool is ð12Þ
mounted on the stage, which is shown in Figure 7.
z2 and z4 can be ignored compared to z1 and z3 .
Point A and point B on the stage are set as driving
Therefore, P0 (x0 , y0 , z0 ) can be simplified as follows
points. Torque around Y-axis and force along Z-axis
8  
can be obtained if point A is driven. Then the rotation > z1
>
> 0
x = lOP
around Y-axis and the displacement along Z-axis are >
> 2l
>
<  OA
outputted on the tip of turning tool. Similarly, the rota- z3
tion around X-axis and the displacement along Z-axis y0 = lOP ð13Þ
>
> 2l
are outputted on the tip of turning tool by driving on >
> OC
qffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffi
>
>
point B. Therefore, the ellipsoid envelope can be : z0 = (z1 + z3 ) + l 2  x  y  l
4 op op
6 Proc IMechE Part B: J Engineering Manufacture 00(0)

Figure 6. Vibration type of the first six modal: (a) the first-order vibration type, (b) the second-order vibration type, (c) the
third-order vibration type, (d) the fourth-order vibration type, (e) the fifth-order vibration type, and (f) the sixth-order vibration
type.

where lOP , lOA , and lOC are distances from origin O to According to equations (13) and (14), ellipse trajec-
points A, P, and C, respectively. tory is decided by the parameters as follows:
If the driving signals z1 and z3 in equation (13) are
set as the sinusoidal signal, then 1. Amplitude of the actuators A1 and A2 .
 2. Initial phase of the actuators a and b.
z1 = A1 sin(vt + a) 3. The distances between the center of the stage and
ð14Þ
z3 = A2 sin(vt + b) the driving points lOA and lOC .
4. Length of the turning tool bar lOP .
Lin et al. 7

Figure 7. The prototype of the novel EVC device: (a) the driving points A and B and (b) the rotating angle u of the stage around X-
or Y-axis, and the length L of the turning tool, and the displacement dx(y) on the tip of turning tool.

According to the simulation results, the driving posi-


tion distribution and the stiffness requirement are deter-
mined. And all the parameters of the EVC device are
determined. Then the whole structure of the novel EVC
device is designed as shown in Figure 10.

Experiments
Two PSt150/10X10/20 piezoelectric actuators are
selected to generate the driving force. The working
frequency of the piezoelectric actuator is 0–2000 Hz.
The maximum output displacement of the piezoelec-
tric actuator is 18 mm. And the maximum displace-
ment in Z direction of the compliant mechanism is
11.8 mm after the piezoelectric actuator is assembled
to the EVC device. The phase difference of the piezo-
Figure 8. The simplified model of the EVC device. electric actuator power is setup to be 90°. The input
parameters are guaranteed by the driving equipment.
And the input displace is measured by the capacitive
To verify the feasibility of the compliant mechanism displacement sensor. The output displacement is mea-
for ellipsoid envelope output, simulation is conducted sured by the laser distance measuring instrument.
in ANSYS software. Parameters are selected in Table 3. The output displacement is measured by the laser dis-
The coordinates of the simulation output are plotted tance measuring instrument LK-G5000, KEYENCE.
into the ellipse trajectory in the MATLAB software, Sumitomo TP2500 hard alloy coating turning tool is
which are shown in Figure 9. Results show that the applied in this case. The EVC device fixed on the
angle between the projection of the ellipse long axis lathe is shown in Figure 11.
and the coordinate axis in the X-Y plane is influenced Q235 bar is selected as the processing object. After
by initial phase a and b. And the phase difference of rough turning, finish turning is conducted on two sec-
the driving signal a  b will affect the length ratio of tions of the Q235 bar. On one section, the EVC device
the ellipse long axis and short axis. The lengths of the is turned on. On the other section, the EVC device is
ellipse long axis and short axis are determined by lOA , turned off. The same cutting parameters are used dur-
lOC , and lOP . ing the two sections. The main shaft speed is set as

Table 3. Parameters affecting the elliptical trajectory.

A1 (mm) A2 (mm) lOP (mm) lOA (mm) lOC (mm) a (°) b (°)

I 10 10 60 20 20 0 0
II 10 10 60 20 20 0 30
III 15 15 60 20 20 0 45
IV 15 15 60 15 15 0 45
8 Proc IMechE Part B: J Engineering Manufacture 00(0)

Figure 9. Elliptical trajectories with different parameters: (a) spatial elliptical trajectories, (b) projection on the X–Y plane, (c)
projection on the X-Z plane, and (d) projection on the Y–Z plane.

500 r/min. The feed rate is 0.1 mm/r. The back engage-
ment of the cutting edge is 0.1 mm. And the working
frequency of the EVC device is adjusted to 2000 Hz. In
the end, the machined surface of the Q235 bar is shown
in Figure 12.
As shown in Figure 12, cutting surface quality with
the EVC device vibration is obviously superior to the
conventional cutting. Figure 13 shows the two different
turning surfaces with an optical microscope. Results
show that the cutting quality is improved obviously
with the EVC equipment.
The two different cutting surfaces are measured on
Figure 10. The whole structure of the EVC device.
the roughness measuring instrument, which is shown in

Figure 11. The EVC device fixed on the lathe.


Lin et al. 9

2000 Hz. The relationship between the roughness and


the cutting speed is shown in Figure 15. Results show
that the surface roughness decreases with the increase
of the shaft speed during the range of 500–575 r/min.
But the surface roughness increases with the increment
of the shaft speed if the cutting speed is larger than
575 r/min. Therefore, the critical speed of the new EVC
device is closed to 575 r/min.
To obtain the change law of the roughness with the
driving frequency, experiments are conducted with dif-
ferent driving frequencies. The main shaft speed is
500 r/min. The feed speed is 0.1 mm/r. And the cutting
depth is 0.1 mm. Results show that the roughness of
Figure 12. Comparison of the conventional turning and the the bar decreases with the increment of the driving fre-
turning with the EVC device. quency, while the effect is not obvious if the driving fre-
quency is more than 1000 Hz. The change law of the
surface roughness with the driving frequency can be
Figure 14. Results show that roughness of the conven- shown in Figure 16.
tional cutting surface is 9.912 mm and roughness is
3.446 mm on the surface of three-dimensional elliptical
vibration turning.
Conclusion
In order to study the critical speed of the new EVC FACT theory is applied to design an EVC device.
device, the cutting speed is changed under the same Simulation and experiments are conducted to verify the
condition of other cutting parameters. The feed rate is validity of the device. And the influence of parameters
set as 0.1 mm/r, the back engagement of the cutting on the machining effect is discussed. The specific results
edge is set as 0.1 mm, and driving frequency is set as and conclusions are as follows

Figure 13. The turning surface micro-graph with two different machining types: (a) conventional turning and (b) turning with the
EVC device.

Figure 14. Roughness of different machining types: (a) surface roughness of conventional turning and (b) surface roughness with
the EVC device.
10 Proc IMechE Part B: J Engineering Manufacture 00(0)

number of three-dimensional EVC devices with differ-


10 ent characteristics.
9
8 Conventional turning
Roughness(mm)

Turning with the EVC device


Declaration of conflicting interests
7
The author(s) declared no potential conflicts of interest
6
with respect to the research, authorship, and/or publi-
5 cation of this article.
4
3 Funding
500 550 600 650 700 The author(s) disclosed receipt of the following finan-
The main shaft speed(r/min) cial support for the research, authorship, and/or pub-
lication of this article: This project is supported by
Figure 15. Roughness change law with different shaft speeds.
Department of Education of Liaoning Province
(Grant no. JDL2016027), National Natural Science
Foundation of China (Grant no. 51775078), and
Natural Science Foundation of Liaoning Province
10
(Grant no. 20170540123).
9
Roughness
8
Roughness(mm)

ORCID iD
7
6 Sheng Lin https://orcid.org/0000-0001-9886-8446
5
4 References
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