Performance analysis of the longitudinal-torsional ultrasonic milling of Ti-6Al-4V

Pang, Yu; Feng, Pingfa; Wang, Jianjian; Zha, Huiting; Xu, Jifeng

doi:10.1007/s00170-021-06682-7

Cited by 19 publications

(6 citation statements)

References 30 publications

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“…Ultrasonic vibration-assisted milling (UVAM) is converting the high-frequency electrical energy onto the mechanical energy to vibrates the milling tool to obtain intermittent milling process 1 . The intermittent contact between the milling flute and the workpiece decreases the average cutting force as reported by Pang et al 2 during milling Titanium alloy. The UVAM also gives others benefits such as decreasing cutting temperature 3 , extending the tool life 4 , and improving roughness on the side wall 1 .…”

Section: Introductionmentioning

confidence: 55%

“…It has been found that the excessive vibration amplitude such as 10 μm will damage the stability of the cutting process and increases the surface roughness. Pang et al 2 analyzed the UVAM by the effect of the longitudinal-torsional vibration during milling Titanium alloy. An excellent surface integrity and regularity has been achieved when the longitudinal-torsional was utilized.…”

Section: Introductionmentioning

confidence: 99%

“…Recently, the 2D vibrations are also added such as torsional and bending mode into the ultrasonic transducer 11 . Moreover, the torsional and bending mode is required to improve the feasibility of the UVAM 2 .…”

Section: Introductionmentioning

confidence: 99%

See 2 more Smart Citations

Development of Ultrasonic Transducer with Flexure Hinge for Ultrasonic Spindle Milling

Kurniawan¹,

Choo²,

Chen³

et al. 2022

Asian Society for Precision Engineering and Nanotechnology (ASPEN 2022)

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Section: Introductionmentioning

confidence: 55%

Section: Introductionmentioning

confidence: 99%

See 1 more Smart Citation

Development of Ultrasonic Transducer with Flexure Hinge for Ultrasonic Spindle Milling

Kurniawan¹,

Choo²,

Chen³

et al. 2022

Asian Society for Precision Engineering and Nanotechnology (ASPEN 2022)

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“…To Induce a vibration on the tool, excitation can be added using a piezoelectric transducer [9]. The vibration generated by the piezoelectric transducer is added on top of the horn, creating a longitudinal vibration to the tool.…”

Section: Ltvam Induction Systemmentioning

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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“…With the wide application of power ultrasound in advanced machining fields, sandwich piezoelectric transducers are valued and studied in ultrasonic milling [ 1 , 2 ], ultrasonic casting [ 3 , 4 ], and ultrasonic vibration for machining residual stress removal [ 5 , 6 , 7 , 8 , 9 ] because of their good electromechanical conversion characteristics. Although the structure and performance of piezoelectric ceramic transducers for different ultrasonic processing fields are not consistent, the inherent frequency of sandwich piezoelectric transducers is the most important performance parameter, which is the key to achieving high power output and high-efficiency energy conversion in practical applications.…”

Section: Introductionmentioning

confidence: 99%

Research on Inherent Frequency and Vibration Characteristics of Sandwich Piezoelectric Ceramic Transducer

Pan

et al. 2022

Sensors

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Great progress has been made in the field of ultrasonic processing in recent years, and piezoelectric ceramic transducers have been widely used as drive sources. In this paper, a sandwich piezoelectric ceramic transducer is designed, and the vibration of each part of the transducer is analyzed by elastic mechanics and piezoelectric theory. According to its mechanical and electrical boundary conditions, the vibration model of the piezoelectric transducer was established. Based on the equivalent elastic modulus method for simplifying the pre-stressed bolts into a one-dimensional transducer vibration model, the relationship between the one-dimensional axial response frequency of the transducer and the length of each component was obtained. Based on the half wavelength theory, a transducer with the vibration node in the crystal stack and an inherent frequency of 15 kHz was designed and fabricated. In order to verify the natural frequency and vibration characteristics of the piezoelectric transducer, a laser vibration measurement system was built in this study. The vibration characteristics of the transducer under different parameters such as voltage and frequency were analyzed, and the accuracy of the vibration model was verified. The vibration states of the end surface of the transducer and the radial surface were evaluated at the first-order inherent frequency and second-order inherent frequency. The results show that the equivalent simplified model established in this study can effectively design the inherent frequency of the transducer, and the operation at the first-order inherent frequency meets the one-dimensional assumptions of this study. The transducer operating conditions measured in this study also provide a more detailed reference for ultrasonic processing applications.

show abstract

Performance analysis of the longitudinal-torsional ultrasonic milling of Ti-6Al-4V

Cited by 19 publications

References 30 publications

Development of Ultrasonic Transducer with Flexure Hinge for Ultrasonic Spindle Milling

Development of Ultrasonic Transducer with Flexure Hinge for Ultrasonic Spindle Milling

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

Research on Inherent Frequency and Vibration Characteristics of Sandwich Piezoelectric Ceramic Transducer

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