Abstract
In order to realize the connection for metal foil, a longitudinal-torsional compound consolidation vibration system is proposed, and relative experiments are carried out. Firstly, the structure of longitudinal-torsional compound consolidation vibration system was designed, detailed structural design of the compound piezoelectric transducer and the compound horn in the vibration system was carried out, and torsional vibration analysis of the compound horn with spiral grooves was carried out based on mechanical principle. Secondly, modal calculation and harmonic response analysis of longitudinal-torsional compound consolidation vibration system were carried out, and corresponding vibration mode and harmonic frequency were obtained. The effect of structural parameters for the compound horn on the frequency of the consolidation vibration system was analysed, and structural parameters of the compound horn were optimized. Finally, the prototype was made, and the experimental platform was built to test the amplitude. When the frequency is near 20000 Hz, the resonance is achieved in three directions at the same time, and the resonance frequency is 19800 Hz. Through the frequency-scanning test, the maximum longitudinal amplitude of the consolidation vibration system is 16 μm, and the maximum torsional amplitudes of X and Y are 7.9 μm and 8.1 μm. The longitudinal-torsional compound consolidation vibration system can realize the connection of the same and different metal foils and has broad application prospects.
Highlights
Ultrasonic additive manufacturing for metal foil has the advantages of low forming temperature, small deformation, fast speed, and no pollution
To connect metal foils under certain pressure, it is usually achieved under one-dimensional longitudinal vibration mode by the traditional additive manufacturing equipment
A system for use in ultrasonic additive manufacturing processes was invented by Norfolk et al [5], comprising the milling machine or the like and a welded assembly
Summary
Ultrasonic additive manufacturing for metal foil has the advantages of low forming temperature, small deformation, fast speed, and no pollution. Rough the effect of structural parameters of the compound horn on vibration frequency, it can be seen that the change of the length L1 of the small end cylinder, the length L2 of the big end conical part, the diameter D1 of the small end cylinder, the inner diameter D2, and the sector angle β of the big end conical part will affect vibration frequency, and the design size of the compound horn can be obtained from the analysis. E simulation results show that the length L1 (P2) of the small end cylinder and the inner diameter D2 (P3) of the big end conical part have an effect on the longitudinal-torsional frequency of the consolidation vibration system, which are important parameters to be considered in the optimization process. Based on theoretical calculation and optimal design, the prototype of the longitudinal-torsional compound piezoelectric consolidation vibration system for metal foil was made.
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