Work

Performance and Mechanism on Sand Mold Ultrasonic Milling

Year: 2025

Type: article

Abstract: Sand mold milling plays a critical role in digital mold-free casting, but it is prone to damage such as corner collapse, collapse, and cracks during the machining process. To address this issue, ultrasonic vibration was used for sand mold milling in this study. By incorporating the solid–liquid transition model for sand mold cutting and considering the deformation characteristics of the shear zone, a prediction model for ultrasonic milling forces in sand mold was developed and experimentally validated. The results demonstrate that increasing the spindle speed and decreasing the feed rate lead to a decrease in cutting force. At high speeds, there is a 15% error between the dynamic milling force model and experimental values. Compared with conventional processing methods, ultrasonic processing reduces cutting force by 19.5% at a frequency of 25.8 kHz and amplitude of 2.97 μm, minimizes defects like sand particle detachment pits on the surface of sand mold, significantly improves surface quality, and enables precise, stable, high-precision, and efficient sand mold processing.

Source: Coatings

DOI: 10.3390/coatings15060633

Authors: Bailiang Zhuang, Zhongde Shan, Zhuozhi Zhu, Di Ding, Qi Zhao

Institution: China Academy Of Machinery Science & Technology (China)

Language: English

Topic: Advanced machining processes and optimization

Subfield: Mechanical Engineering

Field: Engineering

Domain: Physical Sciences

Open Access status: gold

Estimated APC paid: $3,137

Funder: Jiangsu Science and Technology Department