Investigation of the longitudinal-flexural resonating spindle in ultrasound-assisted grinding of SiCp/Al composites

Abstract

Rotary ultrasonic machining is a cost-effective and precise machining method for hard and brittle materials. Aiming at processing SiCp/Al composites, a rotary ultrasonic grinding spindle is proposed in the present study. Expressions were established to calculate the displacement, rotation angle, bending moment, and shear force of the vibrating elements based on the Mindlin moderate plate theory. Combining continuous and boundary conditions of vibrating elements with the proposed expressions, the vibration model and frequency equation of longitudinal-exural resonating transformer with a large load were established. Then two transformers were designed according to the frequency equation. The resonant characteristics of the transformers were studied using nite element analysis, impedance analysis, and ultrasonic resonance experiments. The obtained results show that the maximum deviation between the resonant frequency and the design frequency of the transformers was 4.95%. Moreover, the maximum deviation of the positions of the pitch circles was 6.51%. It is concluded that the proposed designs have high accuracy. Finally, the orthogonal single-factor experiments of SiCp/Al composites were performed with and without ultrasound. The obtained resultsshow that introducing ultrasonic vibrations signi cantly reduces the grinding force and the surface roughness while improving the surface quality of the SiCp/Al workpiece. The present study is expected to provide experimental fundamentals to further improve the structure of the grinding spindle, optimize process variables of ultrasound-assisted grinding, and improve the processing e ciency.

Rotating Sonotrode Design for Ultrasonic-Assisted Arc Welding of Metal Materials

“…Based on the Mindlin theory, Wu created a rotating sonotrode composed of a three-annular plate-shaped roller end and a conical thin end. The roller end material included brass and gray cast iron, while the thin-end material was 45 steel [36]. On this basis, Fu developed numerical solution software with a MATLAB/GUI interface for a rotating sonotrode, as well as designed a rotating sonotrode with an aluminum-based phenolic resin binder as the roller end material [37].…”

Simulation and Experimental Study of Non-Resonant Vibration-Assisted Lapping of SiCp/Al

“…Wu et al designed a rotary ultrasonic lapping spindle and carried out SiCp/Al machining experiments. Observing and analyzing the surface morphology of SiCp/Al verified that the axial UVM method can also reduce the lapping force and surface roughness [ 17 ].…”