Review on design of hybrid longitudinal-torsional ultrasonic vibration horn for rotary ultrasonic machining (RUM) processes

Abstract

Longitudinal-torsional (L-T) vibration machining process in rotary ultrasonic machining (RUM) technologies has been considered one of the most promising method in order to cope the machining problems of various difficult-to-machine materials (composites, metallic alloys, abrasives, ceramics and glass). However, design complexity of the L-T machining systems keeps it limited for commercial applications. Hybrid L-T horn is the key component to achieve the efficient performance of RUM systems. Design of hybrid L-T horn is highly intricate due to slots geometry, position, and number of slots. At present, there is no study available in the literature specifically focused on the design and implementation of hybrid L-T horn. Therefore, this study systematically describes literature review on the design, simulations and implementation of hybrid L-T vibration horn in RUM applications of difficult-to-machine materials. Furthermore, the present research reveals the critical design parameters of hybrid L-T horn such as incident angle 47.6° gives better surface quality of the machined hole compared to 67.2° at designed resonant frequency 35 kHz.