Abstract
The longitudinal–torsional ultrasonic vibration machining process is popular for machining hard and brittle materials. A longitudinal–torsional ultrasonic vibration system with diagonal slits was designed for the ultrasonic vibration machining process based on the principle of acoustics propagation in this study. Four uniform diagonal slits were cut off on the horn cylinder to transform the longitudinal ultrasonic vibration into a longitudinal–torsional composite motion. A finite element analysis was used to optimize the mechanical structure of the vibration system. Dynamic characteristics of the vibration system were numerically studied, and the relationship of diagonal slits versus the resonance frequency and amplitudes of longitudinal–torsional vibration was analyzed, so that the longitudinal–torsional output amplitude can be optimized by rational choice of structure parameters of diagonal slits. Moreover, the movement locus of the system output end was obtained by utilizing the Origin software, which was proved to be elliptical, and the accuracy of the finite element model was confirmed by comparing numerically and experimentally determined resonant characteristics. In addition, the verification of longitudinal–torsional ultrasonic vibration was proved for the designed ultrasonic vibration system.
Highlights
Along with widespread use of various advanced materials in various industrial sectors such as aerospace, military, precision machinery, and electronics, the machining processes of these materials become one of the research hotspots in the mechanical industry
This study focuses on design and analysis of a longitudinal–torsional ultrasonic vibration system, in which an ultrasonic transducer matched the horn, and the system resonance frequency was designed as 20 kHz based on the longitudinal wave propagation equation set
A kind of longitudinal–torsional horn with diagonal slits was designed for ultrasonic vibration machining process in this study
Summary
Along with widespread use of various advanced materials (such as carbon fiber composite and ceramics) in various industrial sectors such as aerospace, military, precision machinery, and electronics, the machining processes of these materials become one of the research hotspots in the mechanical industry. Keywords Diagonal slits, longitudinal–torsional ultrasonic vibration, finite element analysis, resonance frequency, amplitude
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