Innovative design and analysis of a longitudinal-torsional transducer with the shared node plane applied for ultrasonic assisted milling

2018 ◽  
Vol 233 (12) ◽  
pp. 4128-4139 ◽  
Author(s):  
Chenjun Wu ◽  
Shijin Chen ◽  
Kai Cheng ◽  
Hui Ding ◽  
Caiwei Xiao
Keyword(s):  
Ultrasonic Vibration ◽  
Torsional Vibration ◽  
Longitudinal Vibration ◽  
Piezoelectric Ceramics ◽  
Displacement Sensor ◽  
Innovative Design ◽  
Vibration Transducer ◽  
Milling Operations ◽  
Ultrasonic Assisted ◽  
Vibration Milling

This paper presents an innovative design and development of a longitudinal-torsional ultrasonic vibration transducer. This longitudinal-torsional ultrasonic vibration transducer can be stimulated up by one group of longitudinal piezoelectric ceramics and it has a shared longitudinal and torsional vibration node plane. The longitudinal-torsional ultrasonic vibration transducer consists of two amplitude horns, a mounting flange, and four pieces of axially poled piezoelectric ceramics. Theoretical analysis and formulation of the share vibration node have been studied, which are used to guide the design of the transducer. Five helical grooves are cut off along the circumference of the amplitude horn so as to convert the longitudinal vibration to both longitudinal and torsional vibration at the same time. Simulations have confirmed that each longitudinal-torsional vibration mode has one shared node on the transducer. The vibration amplitude is measured by a laser displacement sensor and the largest longitudinal displacement of longitudinal-torsional ultrasonic vibration transducer reaches 6 µm and torsional displacement reaches 11 mrad when 500Vpp voltage is applied on the transducer. Ultrasonic vibration milling experiments have shown that the longitudinal-torsional ultrasonic vibration transducer has played a great role in the cutting process as the longitudinal-torsional ultrasonic vibration milling decreases the cutting force substantially compared to the convention milling operations.

A type of dual-rotor hybrid ultrasonic motor based on vibration of four side panels

2016 ◽  
Vol 28 (14) ◽  
pp. 1916-1924 ◽  
Author(s):  
Lin Yang ◽  
Xingxing Zhu ◽  
Sisi Di
Keyword(s):  
Torsional Vibration ◽  
Vibration Mode ◽  
Longitudinal Vibration ◽  
Piezoelectric Ceramics ◽  
Ultrasonic Motor ◽  
Outer Diameter ◽  
Operating Voltage ◽  
Vibration Modes ◽  
Bending Vibration ◽  
Longitudinal Vibration Mode

Based on vibration of four side panels, a type of dual-rotor hybrid ultrasonic motor without using the torsional piezoelectric ceramics polarized along the circumferential direction is presented. The first longitudinal and the first bending vibration modes of the four side panels are used to indirectly excite the first longitudinal and the second torsional vibration modes of the stator cylinder. There are rectangle piezoelectric ceramics bonded on both sides of the four side panels, which are uniformly distributed along the circumference of the stator cylinder. One pair of panels on the opposite side is used to indirectly excite the first longitudinal vibration mode of the stator cylinder, and the other pair is used to indirectly excite the second torsional vibration mode. The simulation results, using finite element method software Workbench, reveal the operating principles, and the optimal structure is proposed. The appearance size of the prototype is 27.2 mm × 27.2 mm × 70 mm, while the outer diameter of the stator cylinder is 20 mm. The working frequency of the prototype measured in experiment is 44.7 KHz, which is consistent with the numerical results. According to the major mechanical measurement at 450 Vp−p operating voltage and 3.46 N preload, the stalling torque of the prototype is 8 mN·m and the no-load speed is 140 r/min. The experimental results indicate that the motor can operate in the first longitudinal and the second torsional coupled vibration modes transformed from the first longitudinal and the first bending vibration modes of four side panels.

scholarly journals Ultrasound Effect on the Microstructure and Hardness of AlMg3 Alloy under Upsetting

Materials ◽  
2021 ◽  
Vol 14 (4) ◽  
pp. 1010
Author(s):  
Przemysław Snopiński ◽  
Tibor Donič ◽  
Tomasz Tański ◽  
Krzysztof Matus ◽  
Branislav Hadzima ◽  
...  
Keyword(s):  
Flow Stress ◽  
Ultrasonic Vibration ◽  
Light And Electron Microscopy ◽  
Load Flow ◽  
Forming Limit ◽  
Ultrasonic Vibrations ◽  
Softening Effect ◽  
Simultaneous Application ◽  
Ultrasonic Assisted ◽  
Acoustic Softening

To date, numerous investigations have shown the beneficial effect of ultrasonic vibration-assisted forming technology due to its influence on the forming load, flow stress, friction condition reduction and the increase of the metal forming limit. Although the immediate occurring force and mean stress reduction are known phenomena, the underlying effects of ultrasonic-based material softening remain an object of current research. Therefore, in this article, we investigate the effect of upsetting with and without the ultrasonic vibrations (USV) on the evolution of the microstructure, stress relaxation and hardness of the AlMg3 aluminum alloy. To understand the process physics, after the UAC (ultrasonic assisted compression), the microstructures of the samples were analyzed by light and electron microscopy, including the orientation imaging via electron backscatter diffraction. According to the test result, it is found that ultrasonic vibration can reduce flow stress during the ultrasonic-assisted compression (UAC) process for the investigated aluminum–magnesium alloy due to the acoustic softening effect. By comparing the microstructures of samples compressed with and without simultaneous application of ultrasonic vibrations, the enhanced shear banding and grain rotation were found to be responsible for grain refinement enhancement. The coupled action of the ultrasonic vibrations and plastic deformation decreased the grains of AlMg3 alloy from ~270 μm to ~1.52 μm, which has resulted in a hardness enhancement of UAC processed sample to about 117 HV.

Effect of longitudinal−torsional vibration in ultrasonic-assisted drilling

2016 ◽  
Vol 32 (6) ◽  
pp. 616-622 ◽  
Author(s):  
Saeid Amini ◽  
Meysam Soleimani ◽  
Hossein Paktinat ◽  
Mohammad Lotfi
Keyword(s):  
Torsional Vibration ◽  
Ultrasonic Assisted

scholarly journals Research on Cutting Force and Surface Integrity of TC18 Titanium Alloy by Longitudinal Ultrasonic Vibration Assisted Milling

2021 ◽  
Author(s):  
Weibo Xie ◽  
Xikui Wang ◽  
Erbo Liu ◽  
Jian Wang ◽  
Xiaobin Tang ◽  
...  
Keyword(s):  
Titanium Alloy ◽  
Cutting Force ◽  
Ultrasonic Vibration ◽  
Surface Integrity ◽  
Rotational Speed ◽  
Three Dimensional ◽  
Cutting Temperature ◽  
Surface Residual Stress ◽  
Deformation Layer ◽  
Vibration Milling

Abstract In order to study the influence of rotational speed and amplitude on the surface integrity, TC18 titanium alloy samples were milled by the process of conventional milling and longitudinal ultrasonic vibration assisted milling. The experimental data were obtained by dynamometer, thermometer, scanning electron microscope, X-ray diffractometer and three-dimensional surface topography instrument for observation and analysis. The results show that the rotational speed has a significant effect on the cutting force, cutting temperature, surface morphology and surface residual stress. Compared with ordinary milling, the surface micro-texture produced by ultrasonic vibration milling is more regular, , and with the increase of rotational speed, the influence of ultrasonic vibration on cutting force and cutting temperature decrease. There are adverse effects on surface roughness after ultrasonic vibration superposition. The influence of ultrasonic vibration on the surface residual compressive stress is also greatly reduced when the rotational speed is greater than 2400 rpm. In addition, a certain depth of plastic deformation layer can be formed under the surface of ultrasonic vibration machining, and the depth of deformation layer increases with the increase of vibration.

Research on Milling Force in Ultrasonic Assisted End Milling of Titanium Alloy Thin-Walled Parts

2018 ◽  
Vol 764 ◽  
pp. 252-260
Author(s):  
Feng Jiao ◽  
Cheng Lin Yao ◽  
Li Zhao ◽  
Feng Qi
Keyword(s):  
Titanium Alloy ◽  
Cutting Force ◽  
Ultrasonic Vibration ◽  
End Milling ◽  
Signal To Noise Ratio ◽  
Milling Force ◽  
Alloy Material ◽  
Ultrasonic Assisted ◽  
Thin Walled ◽  
Force Characteristics

Hard machinability of titanium alloy material and poor stiffness of thin-walled part restricted the extensive applications of titanium alloy thin-walled component in aerospace engineering. In order to increase geometric accuracy, a method of ultrasonic vibration assisted (UVA) end milling technology with workpiece vibrating in feeding direction was put forward in this paper, and the corresponding milling force characteristics in UVA milling of titanium alloy TC4 thin-walled workpiece were researched. Through theoretical analysis, the path of cutter tooth in UVA milling was analyzed. The important factors that affect milling force are obtained with the signal to noise ratio analysis. Results show that the radial cutting force in UVA milling is smaller than that in traditional milling. Cutting force fluctuate in high frequency when treated ultrasonic vibration. And the axial cutting feed is the core factor that affects the milling force. The research provides a certain reference for the precision milling of titanium alloy thin-walled parts.

Research on the importance of tool–workpiece separation in ultrasonic vibration–assisted milling

2016 ◽  
Vol 231 (4) ◽  
pp. 600-607 ◽  
Author(s):  
Mohammad Mahdi Abootorabi Zarchi ◽  
Mohammad Reza Razfar ◽  
Amir Abdullah
Keyword(s):  
Experimental Data ◽  
Ultrasonic Vibration ◽  
Vibration Amplitude ◽  
Cutting Speed ◽  
Machining Processes ◽  
Friction Behavior ◽  
Ultrasonic Assisted ◽  
The Times ◽  
Analytical Relations ◽  
First Time

In recent years, various reasons for improvement of performance and efficiency in ultrasonic vibration–assisted machining processes have been reported, which were mostly descriptive and without sufficient analytical and empirical proofs. Among the different machining processes, the least amount of experimental data and analytical relations exist about ultrasonic-assisted milling. In this article, for the first time in ultrasonic-assisted milling, we have determined the times of tool–workpiece engagement and their separation from each other in each vibration cycle and then investigated the influence of vibration amplitude and cutting speed on tool–workpiece effective engagement in ultrasonic-assisted milling. Contrary to ultrasonic-assisted turning, cutting time in each vibration cycle in ultrasonic-assisted milling is different from each other. With the aid of comprehensive experiments at tool–workpiece engagement angles smaller than 90°, we have proved that the main reason for average cutting force decrease in ultrasonic-assisted milling compared with conventional milling is the separation of tool and workpiece that occurs in a portion of each vibration cycle, and other factors such as change of friction behavior have less importance. At investigated tool–workpiece engagement angles, experimental and analytical results agree with each other.

scholarly journals Interface Characteristics and Mechanical Properties of Ultrasonic-Assisted Friction Stir Lap Welded 7075-T6 Aluminium Alloy

Materials ◽  
2020 ◽  
Vol 13 (23) ◽  
pp. 5335 ◽  
Author(s):  
Changshu He ◽  
Zhiqiang Zhang ◽  
Ying Li ◽  
Jingxun Wei ◽  
Menggang Zhai ◽  
...  
Keyword(s):  
Mechanical Properties ◽  
Ultrasonic Vibration ◽  
Fracture Mode ◽  
Fracture Strength ◽  
Shear Fracture ◽  
Friction Stir Lap Welding ◽  
Friction Stir ◽  
Ultrasonic Assisted ◽  
Lap Welding ◽  
Cold Lap

In this work, friction stir lap welding (FSLW) and ultrasonic-assisted friction stir lap welding (UAFSLW) was applied to 6-mm-thick 7075-T6 alloy sheets using three welding tools with the same process parameters. The joint formation, microstructural characteristics, and mechanical properties of the resulting lap joints were then investigated. The results showed that ultrasonic vibration significantly promoted the flow of metal at the interface, enlarged the size of the stirred zone (SZ), and reduced the angle between the hook defect and the interface. During lap shear testing, the FSLW and UAFSLW joints fractured in a similar manner. The fracture modes included tensile fracture, shear fracture, and a mixture of both. Cold lap and hook defects may have served as crack-initiation zones within the joint. Under configuration A (i.e., upper sheet on the retreating side (RS)), all joints failed in the shear-fracture mode. The effective lap width (ELW) of the joint welded using tool T2 was the greatest. This resulted in a higher shear fracture strength. The maximum shear fracture strength of the UAFSLW joint was 663.1 N/mm. Under configuration B (i.e., upper sheet on the advancing side (AS)), the shear fracture strength was greatly affected by the fracture mode. The highest shear fracture strength of the UAFSLW joint, 543.7 N/mm, was welded by tool T3. Thus, under otherwise identical conditions, UAFSLW joints can withstand a greater fracture shear strength than FSLW joints, as ultrasonic vibration helps to mix the material at the interface, thus, enlarging the SZ and diminishing the cold lap defects.

The Effects of Ultrasonic Vibration in Hot Pressing for Microgrooves

2016 ◽  
Vol 861 ◽  
pp. 121-126 ◽  
Author(s):  
Jia Qing Xie ◽  
Tian Feng Zhou ◽  
Yang Liu ◽  
Tunemoto Kuriyagawa ◽  
Xi Bin Wang
Keyword(s):  
Ultrasonic Vibration ◽  
Wave Length ◽  
Fem Simulation ◽  
Maxwell Model ◽  
Mold Surface ◽  
Incomplete Filling ◽  
Surface Flaws ◽  
Generalized Maxwell Model ◽  
Ultrasonic Assisted

Microgrooves with a pitch at wave length level are increasingly needed in the optical system. Conventional, the microgroove forming accuracy is low due to the incomplete filling of the material in the cavity of microgroove mold, and surface flaws occur easily due to the adhesion of the resin material to the mold surface. In this research, the response behavior of resin material subjected to alternating stress is resolved based on Generalized Maxwell model. Finite Element Method (FEM) simulation is carried out to test the microgroove forming effects under the pressing condition without and with ultrasonic vibration. An ultrasonic assisted pressing machine is developed and used to fabricate microgrooves on methacrylic resin surface. Form accuracy and surface quality of microgrooves are confirmed to be improved by comparing the ultrasonic assisted pressing with the conventional forming.

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