A novel approach to fabricate high aspect ratio micro-rod using ultrasonic vibration-assisted centreless grinding

作者：Xu Weixing^*; Wu Yongbo^*

来源：International Journal of Mechanical Sciences, 2018, 141: 21-30.

DOI：10.1016/j.ijmecsci.2018.03.038

• Precision manufacturing
• Advanced material
• Centreless grinding
• Micro-rod
• High aspect ratio
• Ultrasonic vibration

To fabricate micro rods with high aspect ratio, this paper proposed a novel technique using ultrasonic vibration assisted centreless grinding. Based on a comprehensive analysis of the workpiece rotational motion, the whole grinding system stiffness and its geometrical arrangement, a reliable mechanics model was successfully developed for clarifying the material removal process. Relevant experiments conducted showed that the model had captured the mechanics and the major workpiece rounding mechanisms. The workpiece rotational speed can be controlled accurately by the elliptic motion of vibration shoe through the contact friction, and higher vibration amplitude or frequency induces higher workpiece rotational speed. The load on vibration shoe significantly affects its vibration in both bending and longitudinal directions, and the vibration reaches its peak value as the loads on both sides are equal. A preload on one side of the shoe, under which the vibration on the other side comes to be comparatively stable, was identified. To balance the action force from workpiece during grinding, this preload should be applied on the vibration shoe. The grinding length can be up to the shoe's thickness, and workpiece in high aspect ratio with diameter from macro to micro scale can be fabricated easily using the proposed technique. With a step-by-step operation, a micro rod with aspect ratio 310:1 and diameter 42 mu m (less than a human hair) was successfully ground.

• 出版日期2018-6