Vibration Characteristics of the Longitudinal-torsional Composite Inhomogeneous Media Ultrasonic Milling System

doi:10.3901/JME.2019.19.221

Abstract

Abstract: The material is processed by the longitudinal-torsional(L-T)composite ultrasonic vibration milling. Due to the size limitation of the ultrasonic vibration system, the 1/4 wavelength theory is used to design the inhomogeneous media ultrasonic variable amplitude system with the combination of the transducer and the composite horn. Longitudinal-torsional resonance is realized by designing spiral grooves on the horn, and the modal transformation theory of L-T vibration is analyed. The finite element analysis of the L-T composite inhomogeneous media ultrasonic variable amplitude system is studied. The simulation results show that the theoretical value of the natural frequency is close to the simulation value. The deviation is only 0.245%. The performed analysis of helical grooves structural characteristics reveal that the depth has great influence on the natural frequency and the amplitude ratio of the torsional-longitudinal, the influence of the helical angle is second, and the width has the smallest effect on the system performance. The test experimental data of the natural frequency and torsional-longitudinal amplitude ratio have the same trend with the simulation results. Through the comparison of two machining experiments with and without L-T ultrasonic vibration, the results show that the surface roughness values of TC4 and C/C carbon fibre in the L-T ultrasonic vibration milling are dropped by 78% and 47%. The structure of L-T inhomogeneous media ultrasonic vibration milling system is compact, which vibration amplitude and direction can be controlled reliably, meanwhile, the L-T composite ultrasonic vibration milling can effectively improve the workpiece surface processing quality.

Key words: longitudinal-torsional composite vibration, ultrasonic milling, inhomogeneous media, helical grooves, amplitude ratio of the torsional-longitudinal, surface quality

CLC Number:

ZHANG Cunying, ZHAO Bo. Vibration Characteristics of the Longitudinal-torsional Composite Inhomogeneous Media Ultrasonic Milling System[J]. Journal of Mechanical Engineering, 2019, 55(19): 221-231.

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