Abstract
AbstractThe hard and fragile materials like glass, ceramic, titanium-aluminium composites can be machined by ultrasonic machining process. This process is influenced by various parameters such as types of abrasives, types of tool and workpiece materials, different types of horn and tool geometries, frequency, amplitude. The tool is one of the foremost components used in the USM process. The present study is considered the design of a stepped tool using dissimilar materials (tungsten carbide, stainless steel, and titanium) in dynamic conditions. A commercial software, COMSOL Multiphysics, is utilized to analyse the influence of materials on the tool performance. In the modal analysis, there are six different axial and non-axial modes generated for all the tool materials. The preferred mode at which axial mode of vibration is generated at the sixth mode for all the tool materials. The maximum eigen frequency (i.e. 1.3418E5 Hz) is generated in the ultrasonic tool which is made of tungsten carbide. In the harmonic analysis, the maximum von Mises stress is generated in the tool which is made of stainless steel, i.e. 233 MPa. No significant variation is observed for the proposed tool materials through harmonic analysis. Tungsten carbide is one of the appropriate materials for tool design followed by stainless steel and titanium due to its high axial mode of vibration.KeywordsUltrasonic toolTool materialsNumerical analysisModal analysisHarmonic analysis
Published Version
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