Developing a special block sonotrode for ultrasonic-assisted grinding process

Abstract

Despite its known advantages, the ultrasonic-assisted machining process has not been widely introduced into industrial environment. Until the present time, the ultrasonic-assisted machining was only possible for small and light parts, when vibrating the workpiece, or for small and special designed tools, when vibrating the tool. It is demonstrated that due to the changes in mechanical properties of the material, efficiency of the ultrasonic assisted machining is much higher when the vibration is superimposed on the workpiece. Hence, there is an abundant need for development of a proper innovative ultrasonic vibration system which is able to vibrate industrial workpieces of different sizes and weights. To address this requirement, a special designed block sonotrode is invented. The first carried out experiments show that the application of the new ultrasonic system can reduce the grinding forces, surface roughness and thermal damages on the workpiece and increase the G-ratio considerably.