Frequency coupling design of ultrasonic horn with spiral slots and performance analysis of longitudinal-torsional machining characteristics

Pang, Yu; Feng, Pingfa; Ma, Yuan; Zhang, Chenglong

doi:10.1007/s00170-019-04898-2

Cited by 13 publications

(9 citation statements)

References 27 publications

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“…Since horn is a continuous system, therefore there are infinite mode shapes and hence modal frequencies associated with it. In ultrasonic machining systems, tool vibrates in the axial direction, thus only axial modal frequency is important in ultrasonic vibration assisted machining systems either stationary or rotary [7,12,15,19,67]. Simulation results for existing and newly designed ultrasonic horns were later compared to draw conclusion.…”

Section: Methodsmentioning

confidence: 99%

“…They analyzed the influence of step and slot location with a spiral angle of 52° on the modal frequency and vibration amplitude of ultrasonic horn. They achieved significant reduction in cutting forces and improvement in surface quality through coupling of longitudinal and torsional modes of vibration [7]. Lin et al…”

Section: Stepped Hornmentioning

confidence: 99%

“…Therefore, a mechanical horn is required between the transducer and the cutting tool to enhance the amplitude of vibration. Reasonably good machining quality and reduction of forces have been achieved through ultrasonic machining technology [5,[7][8][9].…”

Section: Introductionmentioning

confidence: 99%

“…Stress concentrations can be reduced by incorporating smooth curves at the location of abrupt change in cross section [19,[26][27][28][29][30]. However it may cause reduction in amplitude of vibration as well [7]. The stresses in cylindrical, conical, Gaussian, exponential and catenoidal horn designs are very low, but the amplitude of vibration at the tool end is also extremely less as compared to the step design [6,10,13,20,31,32].…”

Section: Introductionmentioning

confidence: 99%

“…The stresses in cylindrical, conical, Gaussian, exponential and catenoidal horn designs are very low, but the amplitude of vibration at the tool end is also extremely less as compared to the step design [6,10,13,20,31,32]. Slots and holes have been incorporated in some horn designs to increase the amplitude of vibration and reduce stresses [7,26,[33][34][35][36][37][38][39][40]. The lengths and diameters of the cylindrical portions, cross sectional shape (circular to rectangular) [41] and the location of mountings has also been varied to optimize and improve the performance of ultrasonic horn [42][43][44].…”

Section: Introductionmentioning

confidence: 99%

See 4 more Smart Citations

Numerical Evaluation of State of the Art Horn Designs for Rotary Ultrasonic Vibration Assisted Machining of Nomex Honeycomb Composite

Mughal

Qureshi

Qaiser

et al. 2021

Preprint

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Ultrasonic horn plays vital role in achieving vibration amplitude suitable for efficient machining of advanced composites. Due to very high operating frequency of at least of ultrasonic machining system, horn may be subjected to high stresses leading to failure. Mechanical horn is designed to get optimum vibration amplification while keeping stresses in acceptable limits. In this research, state of the art ultrasonic horns were designed with same length and diameters at the transducer side and tool ends under similar operating conditions. All standard and hybrid ultrasonic horns, including some new designs, suitable for machining applications were evaluated through finite element analysis. Modal analysis was performed for computing axial modal frequencies, whereas harmonic analysis was carried out to determine vibration amplitude, stresses and factor of safety. The performance of state of the art ultrasonic horn designs were later compared in terms of vibration amplification, stresses and operating life. The axial modal frequency and amplitude of vibration achieved by barrel, cylindrical-double conical and hollow exponential horns were observed to be greater as compared to the step horn, however the former were prone to greater stress concentrations and low operating life. Reasonably higher vibration amplification, factor of safety and low stresses were achieved by Bezier, cylindrical-catenoidal, cylindrical-Bezier, step-conical, step-catenoidal, step-Bezier, double conical, multistep and multistep-conical horn designs. Remarkably, circular hollow exponential and multistep-conical ultrasonic horns were observed to achieve vibration amplification, factor of safety and operating life higher than that of commercially available step horn.

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Section: Methodsmentioning

confidence: 99%

Section: Stepped Hornmentioning

confidence: 99%