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Vibro-machining technology

一. Objective of Vibro-machining

  By applying vibro-machining units and systems, we can greatly enhance the manufacturing capability of the current machining tools. The bottleneck problems such as low efficiency, low quality and high cost of traditional machining tools can be solved. The final goal is to shorten the R&D cycle, and to realize high value added and long lifetime products.

二. Principle of Vibro-machining

  By adding a 1-axis or multi-axis, low frequency or ultrasonic vibration, the traditional continuous contact machining process converts to an incontinuous, instant and reciprocating contact machining process. The key techniques include vibrator, power circuit, and machine tools. Vibro-machining system can be in the form of machine tool, machine tool accessory, special machine tool, and vibro-machining robot.

三. Advantages of Vibro-machining

1、 For Hard-to-machine materials:

  Vibro-tapping of high-strength materials(including refractory alloy,titanium alloy,stainless steel,high-strength steel, etc): Using cheap China-made screw tap to realize high-efficiency automatic tapping. By saving the cost of expensive special screw tap, the expense of vibro-tapping equipment investment can be recovered quickly.

  Vibro-drilling of hard brittle materials (including quartz glass, tempered glass, ceramics, etc.): The technique can realize ideal hole surface without any braking edge or cloud streak.

  Vibro-reaming of ductile materials (including gun steel, aluminum, etc.): The technique can eliminate deep groove and scratch due to build up edge, when the roughness can be 10~100 times reduced.

2、 For hard-to-machine structures:

  Vibro-turning of weak-stiffness structure (thin wall cylinder, slender rod, etc.): The cutting force can be reduced to 1/10 or less, and the machining deformation reduced obviously.

  Elliptical vibration machining of micro accessory (micro cavity): The cutting force can be reduced to 1/100, and the process system deformation reduced obviously.

  Vibro-lapping and polishing of difficult to reach structure (dead corner, curved surfaces, step surface): The technique makes the precision 1-level higher and the efficiency 2 times better.

  Vibro-drilling of Micro-holes: Using cheap China-made micro drill to realize efficient automatic micro hole drilling, saving the drill bits cost and processing time.

  Vibro-drilling of inclined holes: The technique can realize stable entering and extrusion drilling, the bit life can be significantly increased.

  Vibro-drilling of Small deep hole: The technique can realize small diameter less than 2mm, deep-diameter ratio more than 40 hole efficient drilling. Speed back times can be reduced to 1/10 or less.

  Vibro-drilling of deep holes, vibration deep hole core-drilling: The technique can realize vibration chip breaking, reduce chip-removal space evidently, and improve the stiffness of drill bit, the drilling efficiency and the material utilization.

  Vibro-boring of step deep hole, micro taper hole: The technique can realize vibration chip breaking, suppress the radial vibration and streaks of the boring bar, and improve the boring efficiency.

3、The integrity of hard-to-machine surface:

  Vibration de-burring with longtime stability: Removing the burr of the jet orifice and the throttle edge, ensure the stability of the flow rate or atomization.

  Vibration extrusion strengthening with long lifetime: Eliminating the defects of the inner and surface of the coating, realize surface compressive stress, improve air tightness and fatigue life.

  Vibration stress less machining, vibration de-internal stress with longtime precision: Eliminating the internal and surface stress, and sustaining longtime precision.

四. Breakthrough of Vibro-machining Compared to Traditional Machining

  Using vibro-drilling to substitute high energy drilling: Partially substituting EDM and laser machining and realizing non-recast layer, no burr efficient drilling.

  Using vibro-turning to substitute grinding: Partially eliminating grinding process and other finishing process, improving the global process efficiency.

  Using vibration automatic tapping to substitute manual tapping: Completely changing the backward situation of the machining of hard machining material tapping, small hole tapping, blind hole tapping and manual tapping.

  Using vibration automatic lapping and polishing to substitute manual lapping and polishing: Completely changing the backward situation of manual lapping and polishing of complex surface, dead corner, and step surface.

  Using elliptical vibration machining to substitute high speed milling: Completely solving the problem of high-speed reached milling of micro accessory. 

五. Established Vibro-machining Techniques

1、Vibration tapping technique


Principle of vibration tapping technique, Case of vibration tapping facility
Effects of hard machining materials vibration tapping:
The average tapping torque reduces to 1/15 or less.
Automatic tapping substitutes manual tapping! No tap broken! Times more improved tap life!
Cost-effective screw tap made in China substituting expensive import tap! The cost decreases dramatically!
Facility type:
Vertical machining tools, rocker arm machining tools, swing type machining tools, etc.

 

 

 

 

 

 
 

 

 

 

2、Vibration drilling and reaming technique

Principle of vibration drilling technique, Case of vibration drilling facility
Effects of vibration drilling and reaming:
Chip breaking and exhausting excellently!
The drilling force decreases dramatically! Times more improved drill bit life!
High entrance precision! High straightness accuracy of deep drilling hole! Low exhaust burr!
Facility type:
Vertical machining tools, horizontal machining tools, rocker arm machining tools, etc.
Manual drilling tools, auto feed drilling tools, robot drilling tools, etc.

 

 

 

 

 

 

 

 

 

3、Vibration boring technique


Principle of vibration boring technique, Case of vibration boring facility

Effects of vibro-turning:
Turning force decreases dramatically! The turning precision improves dramatically!
Suppressing the turning chatter and the surface roughness decreases!
The lifetime of hard-machining materials’ cutting tools extends dramatically!
Facility type:
Common lathes, NC lathe and super-precision lathe, etc.

 

 

 

 

 

 

 

4、Vibro-turning technique


Principle of vibro-turning technique, Case of vibro-turning facility

Effects of vibro-turning:
Turning force decreases dramatically! The turning precision improves dramatically!
Suppressing the turning chatter and the surface roughness decreases!
The lifetime of hard-machining materials’ cutting tools extends dramatically!
Facility type:
Common lathes, NC lathe and super-precision lathe, etc.

 

 

 

 

 

 

 

5、Vibration extrusion technique


Principle of vibration extrusion technique, Case of vibration extrusion facility

Effects of vibration extrusion:
The extrusion force decreases dramatically in the same deformation condition!
Suppressing extrusion defects and the surface roughness decreases!
The lifetime of hard-machining materials’ extrusion tools extends dramatically!
Facility type:
Common lathes, NC lathe and pneumatic tools, etc.

 

 

 

 

 

 

 

 

6、Vibration milling technique


Principle of vibration milling technique, Case of vibration milling facility

Effects of vibration milling:
The milling force decreases dramatically, and the milling precision of thin wall parts improves.
Milling defects and the surface roughness decreases!
The lifetime of hard-machining materials’ milling tools extends dramatically!
Facility type:
Conventional milling machine, machining center, micro-miniature milling machine, etc.

 

 

 

 


 

  


Bio-aided manufacturing technology

1. The purpose of bio-aided manufacturing technology

  The applications of various bio-aided manufacturing methods can achieve the rapid manufacturing of complex surface structure and break through ideas and principle of traditional physical and chemical machining methods, which effectively solve bottleneck problem of conventional micro/nano manufacturing such as processing capacity, product functionality, processing efficiency and cost. The final goal is to achieve high added value and multifunctional integration of high-tech products with energy conservation and environmental protection.

2. The basic principles of bio-aided manufacturing technology

  The biology is directly used as approach for achieving various bio-aided manufacturing methods (bio-removing forming, bio-limited forming, bio-replicated forming, bio-jointed forming, bio-growing forming and bio-self-assembled forming) through its characteristics such as physiology, shape, material, forming, structure, heredity. The bio-aided manufacturing technology mainly includes manufacturing processes, products and devices.

3. The advantages of bio-aided manufacturing technology

(1) Complex surface morphology

  The surface morphology of biological prototype is used as template directly to achieve rapid replication of bionic functional surface. This method has many advantages such as low cost, high efficiency, high added value of the product, energy conservation and environmental protection.

(2) Shapes and structures of microparticles

  The microorganism cells are used as forming template of functional particles directly to achieve rapid and batch manufacturing of functional particles, resulting in shape diversity of particle, low cost and enhancement of function.

(3) The jointing for nano interface

  The biological nanostructure is used as configuration material to achieve the jointing of nano interface molecule and bonding of nanostructures. This method has advantages of good interface function, strong adaptability and low cost.

4. The breakthrough of bio-aided manufacturing technology on traditional technology

  Breaking through limitations of traditional physical and chemical machining methods, and thus achieving the top expansion of product manufacturing capability by natural substances.

  Breaking through boundaries of biotic and abiotic objects, and thus achieving the cross and merged applications of biotic objects and mechanical structures.

  Breaking through boundaries of manufacturing process and equipment form, and thus achieving the cross of biological manufacturing process and mechanical manufacturing process.

5. Bio-aided manufacturing technology established by Beihang University

(1) Bio-removing forming

(2) Bio-limited forming

(3) Bio-replicated forming

(4) Bio-jointed forming

(5) Bio-growing forming

(6) Bio-self-assembled Forming

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