Investigation of rotary ultrasonic vibration assisted machining of Nomex honeycomb composite structures

Mughal, Khurram Hameed; Jamil, Muhammad Fawad; Qureshi, Muhammad Asif Mahmood; Qaiser, Asif Ali; Khalid, Fazal Ahmad; Maqbool, Adnan; Raza, Syed Farhan; Ahmad, Shahzad; Zhang, Jianfu; Abbas, Syed Zameer

doi:10.1007/s00170-023-12652-y

Cited by 7 publications

(2 citation statements)

References 29 publications

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“…Considerable effort was required to make minor design alterations throughout the development and production stages. FEA analysis is utilized due to its flexibility, speed, cost-effectiveness, and ability to handle intricate geometries [ 21 , 22 , 23 , 24 ].…”

Section: Introductionmentioning

confidence: 99%

Design and Effect of Resonant Ultrasonic Vibration-Assisted Laser Cladding (R-UVALC) on AlCrFeMnNi High-Entropy Alloy

Mohsan,

Zhang,

Wang

et al. 2024

Materials

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The design of the resonant ultrasonic vibration-assisted laser cladding (R-UVALC) setup involved employing finite element analysis (FEA) to simulate the ultrasonic transducer, horn, and workpiece in a resonance state. The impact of R-UVALC on AlCrFeMnNi high-entropy alloys was assessed using various ultrasonic vibration amplitudes of 0, 5, 10, and 15 µm, with a constant frequency of 20 kHz. Ultrasonic vibrations reduced pores and cracks and increased the clad breadth, melt pool wetting angle, and laser-clad layer consistency. The columnar elongated grains in proximity to the substrate surface underwent a size reduction and transformed into grains with a more equiaxed shape with the utilization of ultrasonic vibrations at an amplitude of 5 µm. Laser cladding performed without ultrasonic vibrations yields two phases: face-centered cubic (FCC) and body-centered cubic (BCC). However, when the coating is exposed to ultrasonic vibrations with an amplitude of 5 µm, it forms a solitary body-centered cubic (BCC) phase. The microhardness tripled compared to the substrate, and the most significant microhardness value was achieved at 5 µm of ultrasonic vibration. The friction coefficient was assessed at an ambient temperature, revealing that an ultrasonic amplitude yields the lowest friction coefficient, demonstrating the excellent wear resistance properties of the coating. The analysis of the 3D surface profile of the wear indicates that the use of ultrasonic aid with a 5 µm amplitude leads to reduced depth of scars, and the primary wear mechanism observed is abrasive and oxidative wear with fewer grooves and debris. In addition, XPS analysis revealed the presence of metal components in an oxidized condition, suggesting that the wear process is oxidative in nature. Integrating the R-UVALC setup into a resonance state can significantly enhance the efficiency of the laser cladding process in the laser cladding field.

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Section: Introductionmentioning

confidence: 99%

Design and Effect of Resonant Ultrasonic Vibration-Assisted Laser Cladding (R-UVALC) on AlCrFeMnNi High-Entropy Alloy

Mohsan,

Zhang,

Wang

et al. 2024

Materials

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“…The machining of a honeycomb composite material is one of the application directions of ultrasonic cutting. The cutting blade is the roller end of a rotating sonotrode, and the characteristic frequency of the sonotrode increases with the increase of blade thickness [29][30][31]. For the ultrasonic gear honing process, the roller end of the sonotrode is usually a gear.…”

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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Rotary ultrasonic assisted machining of aramid fiber–reinforced polymer composite: a numerical and experimental investigation using various cutting tools

Mughal,

Qureshi,

Ahmad

et al. 2024

Int J Adv Manuf Technol

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Investigation of rotary ultrasonic vibration assisted machining of Nomex honeycomb composite structures

Cited by 7 publications

References 29 publications

Design and Effect of Resonant Ultrasonic Vibration-Assisted Laser Cladding (R-UVALC) on AlCrFeMnNi High-Entropy Alloy

Design and Effect of Resonant Ultrasonic Vibration-Assisted Laser Cladding (R-UVALC) on AlCrFeMnNi High-Entropy Alloy

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

Rotary ultrasonic assisted machining of aramid fiber–reinforced polymer composite: a numerical and experimental investigation using various cutting tools

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