Design and experimental investigation on longitudinal-torsional composite horn considering the incident angle of ultrasonic wave

Zhao, Bo; Bie, Wenbo; Wang, Xiaobo; Chen, Fan; Chang, Baoqi

doi:10.1007/s00170-019-04220-0

Cited by 22 publications

(10 citation statements)

References 29 publications

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“…Thus, the axial and circular components were produced at the horn's smaller end, including longitudinal and torsional vibrations, respectively. The mechanism of longitudinal vibration conversion into torsional one via helical slots was described in more detail in our earlier study [43], which findings were used to fabricate the horn with helical slots in this study. A laser displacement sensor (LK-G10, KEYENCE, Japan) was used to measure the torsional (A T ) and longitudinal (A L ) vibration amplitudes of the output end face, which ratio (A T /A L ) is up to 0.52.…”

Section: Methodsmentioning

confidence: 99%

Analytical and experimental investigation on cutting force in longitudinal-torsional coupled rotary ultrasonic machining zirconia ceramics

Chen

Bie

Chang

et al. 2022

Int J Adv Manuf Technol

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Ceramics and other hard-and-brittle materials are very effectively processed by longitudinal-torsional coupled rotary ultrasonic machining (LTC-RUM). However, the cutting force evolution and the effects of processing parameters on the material removal mechanism in LTC-RUM need to be clarified for machining optimization. This paper proposes a cutting force model of the LTC-RUM of zirconia ceramics via the brittle material removal mechanism. Firstly, the kinematic analysis of a single abrasive grain was performed, with further consideration of the material removal volume, the effective contact time, and the impact force per one ultrasonic vibration cycle. Then, the longitudinal-torsional coupled vibration of the core tool was analyzed from the standpoint of wave energy conversion. The analytical model was finalized and experimentally verified by LTC-RUM tests. The cutting force curves predicted via the proposed model were in good agreement with the experimental results. The results obtained are considered instrumental in predicting the effects of processing parameters on cutting force during LTC-RUM of ceramics and their further optimization.

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Section: Methodsmentioning

confidence: 99%

Analytical and experimental investigation on cutting force in longitudinal-torsional coupled rotary ultrasonic machining zirconia ceramics

Chen

Bie

Chang

et al. 2022

Int J Adv Manuf Technol

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“…Therefore, the design and manufacture of ultrasonic horns must be very carefully considered. If the ultrasonic horn is incorrect, it reduces the machining performance and can cause significant damage to the transducer causing damage to the ultrasonic system [10].…”

Section: Horn Designmentioning

confidence: 99%

Procedure in developing a longitudinal-torsional vibration-assisted micro-milling system

Kiswanto,

Fahmi,

Hasymi

et al. 2024

J. Phys.: Conf. Ser.

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Micromachining is an advanced microfabrication technique for micro-sized or micro-accuracy products through subtractive manufacturing such as micro-milling. Vibration-assisted machining (VAM) is a method in which small amplitude vibrations are applied to the tool or workpiece to enhance the fabrication process. Milling results could be improved by adding longitudinal and torsional vibration to the tool using piezoelectric components vibrating at the ultrasonic frequency with an amplitude of less than 1 μm is used. A slip ring is required to transmit electric power from a static structure to a rotating frame. After the power has been transmitted to the system, an ultrasonic horn, called an acoustic horn or sonotrode, amplifies the vibrations at the tool’s tip. Since the excitation vibration is only longitudinal, the magnification of the vibration at the tooltip is also only longitudinal. Grooves are added to the side of the ultrasonic horn to produce torsional vibrations. This vibration is then simulated through finite element analysis software, explicitly using explicit dynamics. A 3D simulation is run for a quarter cycle of micro-milling through a Ti-6Al-4V material. It could be concluded that the LTVAM application may improve machining quality, such as temperature reduction of up to 9%, cutting force reduction of up to 35%, and surface roughness improvement of up to 27%.

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“…In ultrasonic-assisted machining, to give full play to the energy accumulation and amplitude increase in the horn and make the tool obtain a good vibration effect, it is usually designed as a shape with a gradually reduced cross section [ 3 , 4 , 21 , 22 , 23 , 24 ]. Common horn shapes include conical, exponential, stepped and catenary [ 3 , 4 , 25 ]. To facilitate processing, the conical horn is used in this study.…”

Section: Structural Design Of Special Machine Toolmentioning

confidence: 99%

Structural Design of a Special Machine Tool for Internal Cylindrical Ultrasonic-Assisted Electrochemical Grinding

Jiao

Bie

et al. 2023

Micromachines

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During the process of internal cylindrical ultrasonic-assisted electrochemical grinding (ICUAECG), both the workpiece and the conductive grinding wheel are rotating, the machining space is closed and narrow, the electrolyte is difficult to spray into the machining area, and the insulation between the workpiece and the machine bed is challenging. According to the machining characteristics of ICUAECG, the structure of a special machine tool was designed to mitigate these problems. In particular, the rotation, electrolyte supply, electric connection, and insulation modes of the workpiece clamping parts were studied, yielding a novel workpiece clamping- and rotating-device design. This structure can fully use the internal space of the hollow spindle of the machine tool, effectively reduce the external moving parts, and achieve the appropriate liquid injection angle of the electrolyte. The ultrasonic vibration system and its installation mechanism, the dressing device of the conductive grinding wheel, and the electric grinding spindle-mounting and -fixing device were analyzed in detail. Then, a special machine tool for ICUAECG was designed, the operability and feasibility of which were verified by experiments involving conductive grinding wheel dressing and ICUAECG.

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Design and experimental investigation on longitudinal-torsional composite horn considering the incident angle of ultrasonic wave

Cited by 22 publications

References 29 publications

Analytical and experimental investigation on cutting force in longitudinal-torsional coupled rotary ultrasonic machining zirconia ceramics

Analytical and experimental investigation on cutting force in longitudinal-torsional coupled rotary ultrasonic machining zirconia ceramics

Procedure in developing a longitudinal-torsional vibration-assisted micro-milling system

Structural Design of a Special Machine Tool for Internal Cylindrical Ultrasonic-Assisted Electrochemical Grinding

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