Professional Documents
Culture Documents
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
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.
T = ½w (c 3 w) + pwT = ½w vT ð1Þ Figure 1. The relationship between a twist and a wrench.15
Lin et al. 3
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
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%
Order number 1 2 3 4 5 6
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.
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
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 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)
ORCID iD
7
6 Sheng Lin https://orcid.org/0000-0001-9886-8446
5
4 References
3 1. Shamoto E, Suzuki N, Tsuchiya E, et al. Development of
0 500 1000 1500 2000
3 DOF ultrasonic vibration tool for elliptical vibration
cutting of sculptured surfaces. CIRP Ann 2005; 54(1):
The driving frequency(Hz)
321–324.
2. Shamoto E, Suzuki N and Hino R. Analysis of 3D ellip-
Figure 16. Change law of the surface roughness with the tical vibration cutting with thin shear plane model. CIRP
driving frequency. Ann 2008; 57(1): 57–60.
3. Shamoto E and Suzuki N. 11.16—ultrasonic vibration
diamond cutting and ultrasonic elliptical vibration cut-
1. A three-dimensional EVC device with two rota- ting. In: Hashmi S (ed.) Comprehensive materials process-
tions and one translation is proposed based on the ing. Amsterdam: Elsevier, 2014, pp.405–454.
FACT theory. The stiffness matrix of the compli- 4. Jung H, Hayasaka T and Shamoto E. Mechanism and
ant mechanism is derived. The relationship suppression of frictional chatter in high-efficiency ellipti-
between the critical speed and the length of the cal vibration cutting. CIRP Ann 2016; 65(1): 369–372.
tool bar is analyzed. 5. Loh BG and Kim GD. Correcting distortion and rota-
tion direction of an elliptical trajectory in elliptical vibra-
2. Simulation results show that the phase difference
tion cutting by modulating phase and relative magnitude
of the driving signal a b will affect the length
of the sinusoidal excitation voltages. Proc IMechE, Part
ratio of the ellipse long axis and short axis. The B: J Engineering Manufacture 2012; 226(5): 813–823.
lengths of the ellipse long axis and short axis are 6. Nosouhi R, Behbahani S, Amini S, et al. Experimental
determined by lOA , lOC , and lOP . and analytical study of the elliptical vibration-assisted
3. Experiments results indicate that roughness of the turning process with the dynamic friction model. Proc
three-dimensional elliptical vibration turning sur- IMechE, Part B: J Engineering Manufacture 2013;
face is far less than the conventional cutting sur- 228(6): 837–846.
face. The critical speed of the EVC device is closed 7. Amini S, Khosrojerdi MR and Nosouhi R. Elliptical
to 575 r/min. The roughness of the bar decreases ultrasonic–assisted turning tool with longitudinal and
with the increase of the driving frequency. The bending vibration modes. Proc IMechE, Part B: J Engi-
influence is not obvious if the driving frequency is neering Manufacture 2017; 231(8): 1389–1395.
more than 1000 Hz. 8. Zhou X, Zuo C, Liu Q, et al. Development of a double-
frequency elliptical vibration cutting apparatus for free-
form surface diamond machining. Int J Adv Manuf
The above results show that the FACT theory is fea- Technol 2016; 87: 2099–2111.
sible for the EVC device. The successful application of 9. Bai W, Sun R, Gao Y, et al. Analysis and modeling of
the FACT theory in the design of three-dimensional force in orthogonal elliptical vibration cutting. Int J Adv
EVC device will stimulate the development of a large Manuf Technol 2016; 83(5): 1025–1036.
Lin et al. 11
10. Yin Z, Fu Y, Xu J, et al. A novel single driven ultrasonic dimensional elliptical vibration cutting. Proc IMechE,
elliptical vibration cutting device. Int J Adv Manuf Tech- Part C: J Mechanical Engineering Science 2014; 228(7):
nol 2017; 90: 3289–3300. 1208–1222.
11. Lu M, Zhou X and Lin J. Improved memetic algorithm 15. Hopkins JB. Design of parallel flexure systems via freedom
for nonlinear identification of a three-dimensional ellipti- and constraint topologies (FACT). Cambridge, MA: Mas-
cal vibration cutting system. Proc IMechE, Part I: J Sys- sachusetts Institute of Technology, 2008.
tems and Control Engineering 2014; 228(7): 449–460. 16. Hopkins JB and Culpepper ML. Synthesis of multi-
12. Lin J, Lu M and Zhou X. Development of a non- degree of freedom, parallel flexure system concepts via
resonant 3D elliptical vibration cutting apparatus for dia- freedom and constraint topology (FACT)—Part I: princi-
mond turning. Exp Techniques 2016; 40(1): 173–183. ples. Precis Eng 2010; 34(2): 259–270.
13. Li YC, Zhou XQ, Lu MM, et al. Parameters optimization 17. Hopkins JB. Design of flexure-based motion stages for
for machining optical parts of difficult-to-cut materials by mechatronic systems via freedom, actuation and constraint
genetic algorithm. Mater Manuf Process 2013; 29(1): 9–14. topologies (FACT). Cambridge, MA: Massachusetts
14. Lin J, Li Y and Zhou X. Tool path generation for fabri- Institute of Technology, 2011.
cating optical freeform surfaces by non-resonant three-