Longitudinal Ultrasonic Vibration Research Articles

Performance of ultrasonic vibration tools with different longitudinal-torsional ratios in extrusion tapping of Ti-6Al-4V

Longitudinal torsional ultrasonic vibrations with different longitudinal torsional ratios [Formula: see text] were introduced into the extrusion tapping process to explore the effects of ultrasonic vibrations in different vibration directions on extrusion tapping of small blind holes in Ti-6Al-4V. First, the motion trajectory model of longitudinal torsional ultrasonic vibration extrusion tapping (LT-UVET) was established, and the intermittent extrusion separation characteristics of edge teeth during the LT-UVET process were analyzed. In addition, finite element simulation was used to analyze the stress and torque of the LT-UVET process with different [Formula: see text]. The simulation results show that the effective stress and torque of LT-UVET at different [Formula: see text] are reduced compared with conventional extrusion tapping (CET). When the ultrasonic vibration direction coincided with the thread direction ([Formula: see text] = 0.08), the effective stress and torque were the lowest. A tapping experiment platform was built and two ultrasonic tools with different aspect ratios were used to conduct tapping experiments. Experimental results show that the torque of LT-UVET is significantly lower than that of CET. Among them, when [Formula: see text] = 0.08, the effect on torque reduction is more obvious. In addition, LT-UVET can also promote metal flow forming, reduce material accumulation, and improve thread surface integrity.

Numerical Modeling and Optimization of Nomex Honeycomb Core Milling: Influence of Longitudinal and Longitudinal–Torsional Ultrasonic Vibrations

Nomex honeycomb structures (NHCs) have currently experienced significant development, mainly in the aeronautics, aerospace, marine, and automotive sectors. This expansion raises noteworthy challenges related to the improvement of machining excellence, necessitating the use of particular cutting tools and adapted techniques. With this in mind, experimental studies were conducted to analyze the specificities of Nomex honeycomb cores milling by integrating longitudinal ultrasonic vibrations along the cutting tool rotation axis (UCK). However, the high tool speed and the unreachability of the tool-workpiece interface complicate the direct observation of the cutting process. To overcome these challenges, a 3D numerical model was developed to simulate the milling of composite honeycomb structures by integrating longitudinal and longitudinal–torsional ultrasonic vibrations. This model was developed by Abaqus/Explicit software, version 2017. The obtained results indicate that the integration of longitudinal–torsional vibrations allows a reduction in cutting forces by up to 28%, a reduction in the accumulation of material in front of the cutting tool, with a maximum reduction of 30%, and an improvement in the quality of the machined surface.

Experimental investigation of longitudinal torsional composite ultrasonic vibration assisted turning of CuCr1Zr alloy

CuCr1Zr alloy plays an important role in aerospace, energy, electronics and other fields. Due to its excellent properties, the cutting of CuCr1Zr alloy has also become one of the research hotspots. In order to obtain better machining quality at lower cost, a kind of machining system of longitudinal torsional composite ultrasonic vibration assisted turning (LT-UAT) is designed in this paper. The combination of longitudinal vibration and torsional vibration is realized by using vibration mode conversion screw (VMCS). The turning experiments of CuCr1Zr alloy with and without ultrasonic vibration are carried out, and the effects of process parameters on surface quality and chip shape (CS) are studied. The results show that lower surface roughness (SR), better surface topography (ST) and CS can be obtained when the LT-UAT of CuCr1Zr alloy with reasonable process parameters. The optimal combination of process parameters (OCPP) is ultrasonic amplitude of 45 µm, cutting speed of 30 m/min, cutting depth of 0.1 mm, and feed speed of 0.1 mm/rev. When selecting process parameters in actual machining, the closer to the above OCPP, the better. This research helps to promote the development of ultrasonic machining technology, and also promotes the application of CuCr1Zr alloy in more fields.

Unraveling the influence of vibrations on material removal and surface quality in longitudinal ultrasonic vibration–assisted milling of Ti2AlNb intermetallic alloy

Unraveling the influence of vibrations on material removal and surface quality in longitudinal ultrasonic vibration–assisted milling of Ti2AlNb intermetallic alloy

Study on the processing performance of 60% SiCp/Al composite materials assisted by longitudinal and torsional ultrasonic vibration milling

Study on the processing performance of 60% SiCp/Al composite materials assisted by longitudinal and torsional ultrasonic vibration milling

Determination of the absorbed acoustic power of longitudinal vibrations by measuring their amplitude in a chosen area of the waveguide system outside the load

The way of determining the acoustic power of longitudinal ultrasonic vibrations going into the load by measuring the amplitude of longitudinal displacements using an electrodynamic sensor installed near the surface of the waveguide rod is considered. Two possibilities of using the developed method of measurement are analyzed in detail. One of them is based on the registration of the value of longitudinal displacements at the constant position of the electrodynamic sensor in two different states of the ultrasound system: with the load disconnected and after the load is connected, i.e. it uses two measurements at different moments of time, when the states of the system differ from each other. Another way uses two measurements of the amplitude of longitudinal oscillations at two chosen points of the oscillatory system, made at the same time. Formulas have been obtained that make it possible to determine the power entering the load from the measured values and other known values of the system parameters. The role of errors, both in the readings of the sensor and in determining its location on the oscillating system, on the accuracy of calculating the value of the power of the ultrasonic oscillations that went into the load is analyzed.

Ultrasonic vibration-assisted single point incremental forming of hemispherical shaped component using AA3003 material

ABSTRACT Ultrasonic vibration-assisted single point incremental forming is a recent hybrid process variant of the single point incremental forming process. In this process, longitudinal ultrasonic vibration is used as an assistance in the conventional forming process. In this paper, the effect of amplitude of vibration in the ultrasonic vibration assisted single point incremental forming process have been researched. For the same, experimental work has been carried out by forming the hemispherical shaped components using multistage forming strategy. Moreover, numerical simulation work has been carried out using the LSDYNA solver and the results have been discussed in the light of depth of forming and strain distribution. The experimental fracture forming line is also developed for the AA3003 material for single point incremental forming process. High amplitude of vibration of 12 micron with 20 kHz frequency leads to poor formability; however, the lower amplitude of vibration of 8 micron with 30 kHz frequency leads to good formability.

Effects of longitudinal ultrasonic vibration on tool wear behaviors in side milling of GH4169D superalloy

The GH4169D superalloy, a novel Nickel-based material widely acknowledged for its exceptional high temperature strength and fatigue resistance properties, plays a pivotal role in the production of critical components of contemporary aero-engines. The material, however, falls under the category of a typical difficult-to-cut metallic material due to the substantial cutting forces and significant tool wear experienced during the machining process. In this paper, a method of longitudinal ultrasonic vibration assisted side milling (LUVM) was developed to extend tool life. The investigation primarily involved an analysis of tool wear behaviors, including milling force, tool life, morphologies of tool wear, and various underlying wear mechanisms in LUVM and conventional milling (CM) of GH4169D superalloy. The results demonstrate that LUVM exhibits the advantage of reducing milling forces and prolonging tool life in comparison to CM. Throughout the entire milling process, the maximum milling force of LUVM is consistently smaller than that of CM, displaying a comparatively slower growth trend. At the conclusion of machining, while CM reaches a maximum milling force of 360.3 N, the maximum milling force of LUVM (195.9 N) is significantly lower. The tool life of LUVM is 28.2 min, representing a 33 % increase compared to CM (21.2 min). Material adhesion, coating delamination, and built-up edge (BUE) phenomena can be observed on both the tool rake face and flank face in CM. LUVM contributes to mitigation of bonding phenomena, prevention of BUE formation, and avoidance of abrasive wear in comparison to CM. However, it is prone to lead to tool tip chipping. For CM, the tool wear mechanisms include adhesive wear, oxidation wear, abrasive wear and diffusion wear; whereas for LUVM, the tool wear mechanisms comprise of adhesive wear, oxidation wear and diffusion wear.

Investigating mechanisms of debris removal in ultrasonic vibration-assisted EDM drilling

In traditional electrical discharge machining (EDM) of micro-holes, the debris removal becomes increasingly challenging as hole depth increases, significantly affecting the machining of difficult-to-machine materials. To address this issue,we first developed a micro-hole gap flow field model for a novel longitudinal–torsional ultrasonic vibration (LTV) electrode EDM drilling method. We analyzed the effects of three types of electrodes — rotation electrodes, longitudinal ultrasonic vibration (LUV) electrodes, and LTV electrodes — on the flow velocity in the micro-hole interstitial flow field. Next, we simulated the motion of fluid and debris in the interstitial flow field of micro-holes, theoretically verifying the advantage of electrode ultrasonic vibration in enhancing debris removal efficiency. Additionally, we observed the electrode tip morphology, the elemental composition on the electrode surface, and the morphology of the micro-hole inlet/outlet and inner wall to further elucidate the debris removal mechanism and confirm the superior drilling performance of the ultrasonic vibration electrodes. At an optimal ultrasonic amplitude (AL=4μm), the LUV electrode demonstrated improved consistency in the micro-hole inlet/outlet and achieved a micro-hole taper of 0.014°. The material removal rate (MRR) using the LTV electrode reached 5.14 × 105μm3/s, nearly 1.5 times higher rotation electrode. This method successfully produced a positively tapered hole suitable for injector nozzles.

Understanding the mechanisms behind ultrasonic vibration in resistance spot welding of aluminum and steel

An ultrasonic-assisted resistance spot welding process, which can improve the quality of aluminum/steel spot-welded joints, has been developed. However, the mechanism of the thermal-electrical-mechanical behavior caused by the ultrasonic longitudinal vibration to welding process has not been clarified. In this study, the role and impact mechanisms of ultrasonic longitudinal vibration during the welding process to form joints were confirmed by combining the microstructural characterization of the formed joints with the signal analysis of the process, as well as the analysis of the independent finite element numerical calculation results. Additionally, the interface metallurgical reaction behavior, welding defects, fracture behavior, and joint strength characteristics of ultrasonic-assisted aluminum/steel resistance spot welding joints were comprehensively analyzed, and the results indicated that the sizes of the aluminum/steel nuggets decreased. It could be attributed to the competition among multiple ultrasonic effects. Specifically, ultrasonic vibration decreased the contact resistance between the aluminum/steel sheets, whereas the acoustic cavitation and acoustic streaming effects increased the electrical conductivity of molten steel and thermal conductivity of molten aluminum, respectively. Moreover, ultrasonic vibration promoted the radial creep of molten and near-molten aluminum, which expanded in the effective bonding area between the two workpieces. Furthermore, ultrasonic vibration effectively reduced the thickness of the intermetallic compound layer (<3.0 µm), concurrently inhibited the formation of interfacial welding defects. Finally, the peak tensile-shear load of aluminum/steel joints is significantly increased under multiple ultrasonic optimization mechanisms.

Characteristics of 2D Ultrasonic Vibration Incremental Forming of a 1060 Aluminum Alloy Sheet.

Currently, 1060 aluminum alloy is widely applied in the electronics industry, construction, the aerospace field, traffic engineering, decorations, and the consumer goods market for its good chemical, physical, and mechanical properties. In general, excellent processing property is necessary and important for the manufacturing of complicated panels. In this paper, a special 2D ultrasonic vibration incremental forming method is designed to improve its plasticity and mechanical properties. Three kind of processing methods, including traditional single-point incremental forming, longitudinal ultrasonic vibration incremental forming, and 2D ultrasonic vibration incremental forming, are used for the flexible manufacturing of cones and cylindrical cups of 1060 aluminum alloy sheet. Then, micro-hardness tests, residual stress tests, and scanning electron microscopy tests are carried out to probe the changes in micro-structure and mechanical properties and to analyze the effects of different types of ultrasonic vibration on the plasticity and fracture characteristic of 1060 aluminum alloy. It is proven that 2D ultrasonic vibration facilitates the improvement of plasticity and surface qualities of 1060 aluminum alloy better than the other two processing methods. Therefore, the novel 2D ultrasonic vibration incremental forming process possesses substantial application value for the flexible and rapid manufacturing of complicated thin-walled component of aluminum alloy.

Cutting performance of multi-tooth milling cutter for cortical bone longitudinal torsional ultrasonic vibration assisted cutting

Multi-tooth milling cutters have the advantages of minimal surface damages and low cutting forces and are widely used in composite materials milling such as carbon fiber and wood. Cortical bone is a composite biomaterial similar to carbon fiber and wood; however, the cutting performance of multi-tooth milling cutters on bone cutting is unclear. Here, this paper proposes a multi-tooth milling cutter longitudinal torsional ultrasonic vibration assisted milling (LTVUM) method for cortical bone low damage cutting. The cutting performance of sinusoidal and corn edge cutters for cortical bone LTVUM was studied, and its material removal mechanisms were also established. The results indicated that the multi-tooth milling cutter has a smaller average cutting force, and suppressing the chip burrs and tearing damages. Compared to straight edge cutter, the resultant cutting forces of sinusoidal and corn edge cutters are decreased by 52.58%–61.01% and 45.60%−65.96%. The reason is that the secondary cutting edge of multi-tooth cutter can participate in cutting, reducing the tool squeeze interference. This work provides experimental guidance for the application of multi-tooth milling cutters LTVUM in bone cutting.

A comprehensive study of ultrasonic-assisted gas metal arc welding of high-strength steel

The present study investigated longitudinal ultrasonic vibrations applied uniformly perpendicular to the weld line as an efficient approach in the ultrasonic-assisted gas metal arc welding (U-GMAW) of high-strength steel. The penetration depth, microstructure, microhardness, mechanical properties, and corrosion of welded joints produced from GMAW and U-GMAW were experimentally explored at different welding conditions to evaluate their performance. The experimental findings show that welded joints produced by U-GMAW have a maximum ultimate tensile strength (UTS) of 18.7 %, while showing 35.4 % elongation and 57.4 % toughness compared to the GMAW-welded joints at optimal conditions. The surface morphology analysis of the welded joints emphasizes that the dendritic microstructures generated by U-GMAW are finer than the dendritic microstructures generated by GMAW. Moreover, the microhardness of welded joints produced by U-GMAW method is higher than the GMAW-welded joints. The results of the polarization test also confirm that the corrosion rate of GMAW-welded and U-GMAW-welded joints are 360 and 1.60 µm/year, respectively with a power of 30 %. These results show that the corrosion rate of welded joints produced by GMAW is much higher than the one produced by U-GMAW.

Longitudinal ultrasonic vibration effects on grinding mechanism in side and end grinding of 2.5D Cf/SiC composites

Longitudinal ultrasonic vibration effects on grinding mechanism in side and end grinding of 2.5D Cf/SiC composites

Investigation on cutting forces and tool wear in high-speed milling of Ti-6Al-4V assisted by longitudinal torsional ultrasonic vibrations

Investigation on cutting forces and tool wear in high-speed milling of Ti-6Al-4V assisted by longitudinal torsional ultrasonic vibrations

Precision Grinding Technology of Silicon Carbide (SiC) Ceramics by Longitudinal Torsional Ultrasonic Vibrations.

Silicon carbide (SiC) ceramic material has become the most promising third-generation semiconductor material for its excellent mechanical properties at room temperature and high temperature. However, SiC ceramic machining has serious tool wear, low machining efficiency, poor machining quality and other disadvantages due to its high hardness and high wear resistance, which limits the promotion and application of such materials. In this paper, comparison experiments of longitudinal torsional ultrasonic vibration grinding (LTUVG) and common grinding (CG) of SiC ceramics were conducted, and the longitudinal torsional ultrasonic vibration grinding SiC ceramics cutting force model was developed. In addition, the effects of ultrasonic machining parameters on cutting forces, machining quality and subsurface cracking were investigated, and the main factors and optimal parameters affecting the cutting force improvement rate were obtained by orthogonal tests. The results showed that the maximum improvement of cutting force, surface roughness and subsurface crack fracture depth by longitudinal torsional ultrasonic vibrations were 82.59%, 22.78% and 30.75%, respectively. A longitudinal torsional ultrasonic vibrations cutting force prediction model containing the parameters of tool, material properties and ultrasound was established by the removal characteristics of SiC ceramic material, ultrasonic grinding principle and brittle fracture theory. And the predicted results were in good agreement with the experimental results, and the maximum error was less than 15%. The optimum process parameters for cutting force reduction were a spindle speed of 22,000 rpm, a feed rate of 600 mm/min and a depth of cut of 0.011 mm.

A comparative study of limit diagram of ultrasonic-assisted and conventional hot incremental forming of Ti-6AL-4V alloy

Electric hot incremental forming (EHIF) technique is a novel sheet metal forming method for low-formability materials like Mg and Ti-6Al-4V alloys. There are some defects in EHIF including low surface quality, unexpected sheet tear, and oxidation of the fabricated workpieces. These defects limit its widespread use. In this article, longitudinal ultrasonic vibrations of forming tools are used for Ti-6Al-4V sheets in the EHIF process. This technique led to a significant reduction of friction coefficient and improvement of workpieces’ surface quality. Also, a combination of mechanical vibrations and heat reduced the phase transformation temperature of α phase (HCP structure) to the more formable β phase (BBC structure) at 600 °C. It improved Ti-6Al-4V sheets’ formability. In this study, various tensile and compressive strains were created by manufacturing different geometries such as cone, frustum, torispherical, and five-lobe. These strains are used to compare the forming limit diagram of the ultrasonic-assisted and conventional hot incremental forming. The design of the experiment and analysis of variance were employed to identify the optimum condition for creating the largest strains. Also, effective parameters were optimized by response surface methodology. Then major and minor strains for both techniques were compared. Achieved strains in all types of geometries for ultrasonic-assisted technique were higher than those achieved by a conventional process.

Optimizing Processing Parameters and Surface Quality of TC18 via Ultrasonic-Assisted Milling (UAM): An Experimental Study.

This study conducted longitudinal ultrasonic-assisted milling (UAM) tests and optimized a combination of milling technological parameters to achieve high-quality machining of TC18 titanium alloy. The motion paths of the cutter under the coupled superposition states of longitudinal ultrasonic vibration and end milling were analyzed. Based on the orthogonal test, the cutting forces, cutting temperatures, residual stresses, and surface topographical patterns of TC18 specimens under different UAM conditions (cutting speeds, feeds per tooth, cutting depths, and ultrasonic vibration amplitudes) were examined. The differences between ordinary milling and UAM in terms of machining performance were compared. Using UAM, numerous characteristics (including variable cutting thickness in the cutting area, variable cutting front angles of the tool, and the lifting of the cuttings by the tool) were optimized, reducing the average cutting force in all directions, lowering the cutting temperature, increasing the surface residual compressive stress, and significantly improving the surface morphology. Finally, fish scale bionic microtextures with clear, uniform, and regular patterns were formed on the machined surface. High-frequency vibration can improve material removal convenience, thus reducing surface roughness. The introduction of longitudinal ultrasonic vibration to the end milling process can overcome the limitations of traditional processing. The optimal combination of UAM parameters for titanium alloy machining was determined through the end milling orthogonal test with compound ultrasonic vibration, which significantly improved the surface quality of TC18 workpieces. This study provides insightful reference data for subsequent machining process optimization.

Modeling of grinding force in longitudinal ultrasonic vibration–assisted grinding alumina ceramics and experimental evaluation

Modeling of grinding force in longitudinal ultrasonic vibration–assisted grinding alumina ceramics and experimental evaluation

Groove bottom material removal mechanism and machinability evaluation for longitudinal ultrasonic vibration–assisted milling of Al-50wt% Si alloy

Groove bottom material removal mechanism and machinability evaluation for longitudinal ultrasonic vibration–assisted milling of Al-50wt% Si alloy