A Piezoelectric Servo Feed Drive for Electro Discharge Machining System Industrial Applications Using Linear Ultrasonic Motor

Abstract

A new servo drive for electro discharge machining industrial applications is presented in this paper. The development processes of the servo feed drive have passed through three main stages. The first stage focused on design and development of a linear piezoelectric ultrasonic motor. The second one concentrated on development of an electronic driver and its embedded software. The integration, testing, and validation in electro discharge machining system, was the last stage of the development iifecycle. The linear piezoelectric ultrasonic motor consists of three main parts, the stator, rotor, and sliding element. The motor design process, basic configuration, principles of motion, finite element analysis, and experimental examination of the main characteristics are discussed in this paper. The electronic driver of the ultrasonic motor consists of two main stages, the booster and piezoelectric amplifier. The piezo amplifier consists of four output transistors, a push-pull and bridge, connected in order to achieve the necessary electrical parameters to drive and control the motor servo feed drive traveling speed. The essential expérimentai arrangement to implement arjd examine the developed ultrasonic servo feed drive in an electro discharge machining system was carried out. The initial results showed that the servo drive is abie to provide: a r-eversible directional of motion, no-load traveling speed equal to 28 mm per s. maximum load of 0.78N, a resolution <50p.m, arid a dynamic time response <10ms. The electr-on microscopic micrv examination into the machined samples showed that: ultr-asonic servo drive showed a clear improvement in the surface profile finish, a notable reduction in the stability, processing time, material removal rate, ar-cing, and short-circuiting teething phenomena. This was verified by assessing the electrode movements, the variations of the inter electrode gap voltage, current, and feedback control signals.

Advancement in Ultrasonic Vibration and Magnetic Field Assisted Micro-Edm Process: An Overview

“…It has been considered to be an outstanding machining process to produce smaller complex structures, which have wider scope of applications in aerospace industries. Machining performance of cryogenically treated tool electrodes and machining of sintered diamond have also been observed by researchers [19,20]. For micro-EDM, the most important applications are small precision cutting punches and dies, precision moulds, components for medical engineering, sensors and optics, watch making (gears and holes) or the production of small multi-component electrodes.…”

“…A new piezoelectric ultrasonic servo control feed drive for electro discharge machining system industrial applications using piezoelectric ultrasonic technology is developed. The developed servo drive is validated successfully in EDM [20].…”

A Standing Wave Piezoelectric Ultrasonic Motor Using a Single Flexural Vibration Ring Transducer

“…They have compact size, high force density, simple mechanical structure, slow speed without additional gear or spindle, high torque, nonmagnetic operation, freedom for constructional design, very low inertia, fast dynamic time responses, direct drive, fine position resolution, miniaturization and noiseless operation. These criteria gave them the potential to be used in a number of industrial applications [9][10][11][12][13][14][15][16]. Demanding and careful examination for these applications reveals that there are apparent teething issues.…”

Research on a Linear Piezoelectric Actuator Using T-Shape Transducer to Realize High Mechanical Output

“…Several parameters were defined as design parameters, as described in Equation (8), to investigate their contributions to the frequency variations of Mode A and Mode B, which are called sensitivities to the modal frequencies. The sensitivities of the design parameters were calculated in ANSYS and shown in Figure 5, where the x axis represents the corresponding variance ratio to their original values and the y axis represents the corresponding resonant frequencies of Mode A and Mode B.…”

“…Recently, bonded-type motors, which are small in size, have attracted many researchers' interests, but their extremely low thrust is a serious drawback. In particular, some kinds of bonded-type motors' thrusts are below 1 N [5][6][7][8], while a few of the bonded-type motors' thrusts have been improved to reach a value of less than 10 N [9][10][11][12]. Moreover, the excitation voltage, applied on the ceramics, has a limit due to the insulation and weakness of the bond.…”