Advances in rotary ultrasonic machining system for hard and brittle materials

Huilin Zhou,Pingfa Feng,Dingwen Yu,Jianfu Zhang,Zhijun Wu,Wanchong Cai

doi:10.1177/1687814019895929

Huilin Zhou, Pingfa Feng + Show 4 more

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https://doi.org/10.1177/1687814019895929

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Abstract

Rotary ultrasonic machining has been widely used for machining of hard and brittle materials due to the advantages of low cutting force, high machining accuracy, and high surface integrity. Focusing on the development of specialized rotary ultrasonic machining systems, this article summarizes the advances in the functional components and key technologies of rotary ultrasonic machining systems for hard and brittle materials, including the ultrasonic generator, power transfer structure, transducer, ultrasonic horn, and cutting tool. Developments on the automatic frequency tracking method, the establishment of an electrical compensation model for power transfer, the energy conversion characteristics of piezoelectric materials and giant magnetostrictive materials, and the design methods for the ultrasonic horn and cutting tool were elaborated. The principle of magnetostrictive energy conversion, output amplitude characteristics of a giant magnetostrictive transducer, and high-power giant magnetostrictive rotary ultrasonic machining systems were also presented. Future research and developments of rotary ultrasonic machining systems regarding the ultrasonic generator, amplitude stability, energy conversion efficiency, vibration mode, and system integration were finally discussed.

Highlights

The traditional ultrasonic machining method uses an ultrasonic vibration tool for abrasive hammering, polishing, hydraulic impact, and the resulting cavitation in an abrasive liquid medium, which causes material removal from the workpiece surface
In traditional ultrasonic machining, the cutting tool with high-frequency vibration has an indirect effect on the workpiece due to suspended abrasive particles; it is difficult to establish an accurate motion model, and the removal rate and machining efficiency of the machined surface cannot be predicted accurately due to the irregular movement of the abrasive particles.[2]
Advances in rotary ultrasonic machining system (RUMS) for hard and brittle materials were reviewed in this article, and current research and development problems and future directions of RUMSs were investigated

Summary

Introduction

The traditional ultrasonic machining method uses an ultrasonic vibration tool for abrasive hammering, polishing, hydraulic impact, and the resulting cavitation in an abrasive liquid medium, which causes material removal from the workpiece surface. It includes an ultrasonic generator, a power transfer structure, a transducer, an ultrasonic horn, a cutting tool, and other functional components. Many scholars have developed and applied different ultrasonic generators in various fields, such as ultrasonic cleaning,[11] ultrasonic welding,[12,13] and processing of hard and brittle materials.[14] Shen[15] designed an intelligent digital controlled ultrasonic generator It can set the output power and achieve automatic tracking of resonant frequency. The theory and structural design of LCIPT technology are well developed in RUMSs. due to the electrical impedance characteristics of the transducer in the resonant state and the leakage inductance of the loosely coupled transformer, it is necessary to conduct additional studies on matching the electrical compensation. The four-terminal network method and the analytical method are limited to the design of the horn structure, and it is difficult to establish an accurate analytical model for complex structures due to the

Research methods

Conclusion