Design and analysis of different horn profiles using FEM for vibration assisted machining

Kartheek, G.; Krishna, P. Radha

doi:10.1007/s41939-021-00108-3

Cited by 3 publications

(1 citation statement)

References 29 publications

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“…The larger the cross-sectional ratio is, the higher the amplification factor. The stepped acoustic sonotrode has a large amplification factor, but stress concentration readily occurs at the variable section of the acoustic sonotrode, and the safety factor of the acoustic sonotrode is low [12][13][14][15]. In order to address the issue of stress concentration at the variable cross-section of the stepped horn, it is usually necessary to design a transition section at the variable cross-section.…”

Section: Introductionmentioning

confidence: 99%

Rotating Sonotrode Design for Ultrasonic-Assisted Arc Welding of Metal Materials

Mao,

Yang,

Chen

et al. 2024

Materials

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In the process of the ultrasonic-assisted arc welding of metal materials, traditional ultrasonic application methods, such as the low-frequency impact of ultrasonic horns on a base material, can easily cause the non-fusion defect. In order to solve this problem, a rotating sonotrode with a groove and double thin ends was designed in this study. The ultrasonic vibration is transmitted into the weld pool by the rolling of the sonotrode on both sides of the weld. The resonant frequency was set at 50 kHz. Firstly, based on the Mindlin theory, a rotating sonotrode without a groove was designed by solving the frequency equation and by conducting a finite element simulation. Secondly, the effects of the groove, perforation, and transition mode on the resonant frequency, stress distribution, and amplification factor were investigated by finite element simulation. Finally, the optimum rotating sonotrode with a groove was obtained. The results show that the size of a rotating sonotrode that has a small frequency error can be obtained by using the discrete interval solver method combined with finite element simulation. The groove can significantly reduce the resonant frequency. The stress concentration can be effectively reduced by using the elliptical transition mode. The resonant frequency and amplification factor of a rotating sonotrode with a groove could be effectively adjusted by a method of double-position joint perforation. The final resonant frequency was 49.721 kHz and the amplification factor was 3.02. This study provides an effective design method for a sonotrode with double thin ends and a groove structure.

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Section: Introductionmentioning

confidence: 99%

Rotating Sonotrode Design for Ultrasonic-Assisted Arc Welding of Metal Materials

Mao,

Yang,

Chen

et al. 2024

Materials

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Hybrid Machining: A Review on Recent Progress

Nor Hamran,

A. Ghani,

Ramli

et al. 2024

Springer Proceedings in Materials

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Performance evaluation of spot cooled vibration assisted turning for Ti6Al4V alloy

Kartheek

Krishna

2023

Proceedings of the Institution of Mechanical Engineers, Part B:

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In the present work, a hybrid modular machining technology was designed for machining of Ti6Al4V alloy. Ultrasonic machining was integrated with vortex tube based spot cooling system with CO2 gas as working fluid for achieving the cumulative advantage of both, which is termed as Spot Cooled Vibration Assisted Turning (SCVAT). Its performance is evaluated and compared with Conventional turning, Vibration Assisted Turning and Vortex tube based spot cooling under constant machining conditions. The vibration and cooling parameters were also kept constant wherever applicable. The results showed a significant reduction in cutting temperature (30.98%), surface roughness (65.97%), and tool wear (75.03%); however, cutting forces are increased slightly compared to dry cutting. Compressive surface residual stresses were generated on the machined surface in SCVAT.

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Design and analysis of different horn profiles using FEM for vibration assisted machining

Cited by 3 publications

References 29 publications

Rotating Sonotrode Design for Ultrasonic-Assisted Arc Welding of Metal Materials

Rotating Sonotrode Design for Ultrasonic-Assisted Arc Welding of Metal Materials

Hybrid Machining: A Review on Recent Progress

Performance evaluation of spot cooled vibration assisted turning for Ti6Al4V alloy

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