Ultrasonic vibration assisted manufacturing of high-performance materials by Fuda Ning, B.S., M.S. A Dissertation In Industrial, Manufacturing, and Systems Engineering Submitted to the Graduate Faculty of Texas Tech University in Partial Fulfillment of the Requirements for the Degree of DOCTOR OF PHILOSOPHY Approved Dr. Weilong Cong Chair of Committee Dr. Hong-Chao Zhang Dr. Golden Kumar Dr. George Zhuo Tan Dr. Wei Li (Dean’s Representative) Mark Sheridan Dean of the Graduate School May, 2018 Copyright 2018, Fuda Ning Texas Tech University, Fuda Ning, May 2018 To My Family and Fleeting Time. ii Texas Tech University, Fuda Ning, May 2018 ACKNOWLEDGMENTS First and foremost, I would like to express the deepest appreciation to my advisor, Dr. Weilong Cong, for his supervision and tremendous help throughout the past few years. He continually conveyed a rigorous attitude toward research and scholarship, which inspired me all the time. This dissertation would not have been completed without his professional guidance. I would like to thank my committee members, Dr. Hong-Chao Zhang, Dr. Golden Kumar, and Dr. George Zhuo Tan, for their valuable advice on my dissertation. I also want to thank Dr. Wei Li to serve as the Dean’s Representative for my defense. My sincere appreciation goes to the U.S. National Science Foundation for the financial support through award CMMI-1538381. I would like to extend my thanks to the Gradual School at Texas Tech University for the Doctoral Dissertation Completion Fellowship to enable me to devote full-time effort to finalizing this dissertation in the very last year of my Ph.D. study. Special thanks to the members of Dr. Cong’s group, Mr. Yingbin Hu, Mr. Hui Wang, and Mr. Yuanchen Li. Working with all of you at Texas Tech University has been becoming an unforgettable experience. This journey would not have been possible without the support of my family. I am especially grateful to my parents and my wife who always support me emotionally and encourage me in all of my pursuits. iii Texas Tech University, Fuda Ning, May 2018 TABLE OF CONTENTS ACKNOWLEDGMENTS .......................................................................................... III ABSTRACT ................................................................................................................ XII LIST OF TABLES ..................................................................................................... XIV LIST OF FIGURES .................................................................................................... XV CHAPTER I .................................................................................................................. 1 INTRODUCTION ........................................................................................................ 1 1.1 Background and motivation ............................................................................ 1 1.2 Research questions .......................................................................................... 3 1.3 Research goal and objective ............................................................................ 5 1.4 Research methodology .................................................................................... 6 1.5 Significance of the research............................................................................. 7 1.6 Structures of this dissertation .......................................................................... 7 References .................................................................................................................. 8 CHAPTER II .............................................................................................................. 11 A LITERATURE REVIEW ON ULTRASONIC VIBRATION-ASSISTED (UV- A) MANUFACTURING PROCESSES .................................................................... 11 Abstract .................................................................................................................... 11 2.1 Background ................................................................................................... 12 2.2 UV-A mechanical manufacturing processes ................................................. 13 2.2.1 UV-A conventional machining .............................................................. 13 2.2.2 UV-A densification ................................................................................ 16 2.2.3 UV-A forming ........................................................................................ 19 2.2.4 Ultrasonic consolidation......................................................................... 21 2.2.5 Remarks on the effects of ultrasonic vibration ...................................... 24 2.3 UV-A thermal manufacturing processes ....................................................... 25 2.3.1 Nonlinear effects of ultrasonic vibration on liquid melting materials ... 25 2.3.2 UV-A thermal non-traditional machining .............................................. 27 2.3.3 UV-A casting ......................................................................................... 29 iv Texas Tech University, Fuda Ning, May 2018 2.3.4 UV-A fusion welding ............................................................................. 33 2.3.5 UV-A laser cladding .............................................................................. 35 2.4 Concluding remarks ...................................................................................... 37 References ................................................................................................................ 38 CHAPTER III ............................................................................................................. 46 ULTRASONIC VIBRATION-ASSISTED (UV-A) HOLE-MAKING OF CFRP COMPOSITES: A COMPARISON WITH CONVENTIONAL GRINDING ...... 46 Abstract .................................................................................................................... 47 3.1 Introduction ................................................................................................... 47 3.1.1 Properties and applications of CFRP composites .................................. 47 3.1.2 Drilling in CFRP composites ................................................................. 48 3.2 Experimental conditions and measurement procedures ................................ 50 3.2.1 Properties of workpiece material ........................................................... 50 3.2.2 Experimental set-up and conditions ....................................................... 51 3.2.3 Measurement procedures for output variables ....................................... 53 3.3 Experimental results and discussions ............................................................ 56 3.3.1 Effects on cutting force .......................................................................... 56 3.3.2 Effects on torque .................................................................................... 59 3.3.3 Effects on surface roughness .................................................................. 60 3.3.4 Effects on hole diameter......................................................................... 62 3.3.5 Effects on material removal rate ............................................................ 63 3.4 Conclusions ................................................................................................... 65 References ................................................................................................................ 66 CHAPTER IV ............................................................................................................. 69 ULTRASONIC VIBRATION-ASSISTED (UV-A) HOLE-MAKING OF CFRP COMPOSITES: DESIGN OF EXPERIMENT WITH A CUTTING FORCE MODEL ....................................................................................................................... 69 Abstract .................................................................................................................... 70 4.1 Introduction ................................................................................................... 70 v Texas Tech University, Fuda Ning, May 2018 4.1.1 Drilling of CFRP composites ................................................................. 70 4.1.2 Cutting force in RUM of CFRP composites .......................................... 71 4.1.3 Purpose of the chapter ............................................................................ 72 4.2 Mechanistic predictive model and design of experiments ............................ 72 4.2.1 Mechanistic predictive model for cutting force in RUM of CFRP composites ............................................................................................. 72 4.2.2 Experimental verification for mechanistic predictive model ................. 76 4.2.3 Design of Experiments ........................................................................... 77 4.3 Experimental results and discussions ............................................................ 79 4.3.1 Main effects on cutting force ................................................................. 79 4.3.2 Two-factor interaction effects on cutting force ...................................... 81 4.3.3 Three-factor interaction effects on cutting force .................................... 82 4.4 Conclusions ................................................................................................... 83 References ...............................................................................................................