Abstract
Ultrasound has been adapted in several industrial and manufacturing applications. In this study, an ultrasonic milling system, which can vibrate a rotating tool, was designed and fabricated. Firstly, a lead zirconate titanate (PZT) was designed using finite element analysis, and the obtained peak impedance value of 47.2 ㎑ agreed well with the fabricated PZT value of 48.0 ㎑. Additionally, an aluminum waveguide with two PZT actuators was analyzed, whose impedance characteristic was predicted to be 43.8 ㎑. Consequently, a milling waveguide was fabricated using the analysis results. The impedance value of the fabricated waveguide was measured to be 42.7 ㎑, which was consistent with the finite element analysis result with an error of 2.6 %. The rotational speed and power output were measured to be 10,001 rpm and 122.6 W. Thus, the developed milling waveguide can be applied to the milling process of high-hardness metals.
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