Novel ultrasonic horn design for machining advanced brittle composites: A step forward towards green and sustainable manufacturing

Mughal, Khurram Hameed; Qureshi, Muhammad Asif; Raza, Syed Farhan

doi:10.1016/j.eti.2021.101652

Cited by 21 publications

(9 citation statements)

References 45 publications

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“…A novel horn design by using 3rd order polynomial equation was developed and designed by Mughal et al [5]. They used the modal and harmonic analysis module of ANSYS in their analysis for evaluation of the performance of various horns (step, catenoidal, quadratic Bezier, cubic Bezier, Gaussian, etc.)…”

Section: Figure 1 the Basic Setup Of Usm And Its Partsmentioning

confidence: 99%

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Design and Analysis of Hollow Catenoidal Horn Profile for Ultrasonic Machining of Composite Materials

Mutahir

Rehman

2022

J. Stud. Sci. Eng.

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The composite materials Si/AlC, crystal quartz, and ceramic glass are becoming an important part of the present society in many engineering and non-engineering fields. Conventional methods available for machining these materials have many flaws due to which their application on large scale is restricted. A non-conventional process known as ultrasonic machining (USM), can be implemented for machining of these materials effectively. Anyhow machining efficiency of USM greatly depends upon its horn design and therefore in the present study a horn based on a catenoidal profile with aluminum and titanium material for USM was designed and developed by using solid works and ANSYS. Modal and harmonic analysis was done on the horn for computation of various parameters of interest such as resonant frequency, amplitude vibration and equivalent stresses. After the computation of the results, they were analyzed and compared with those available in the literature in terms of stresses and magnification factor for their validation comparison with literature, it was found that an aluminum catenoidal horn shows higher magnification with the least stress magnitude as compared to horns avail-able in the literature and hence can be used in USM as a replacement for existing horns.

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Section: Figure 1 the Basic Setup Of Usm And Its Partsmentioning

confidence: 99%

“…The solution of the above equation gives displacement as a function of its position and time as given below (5).…”

Section: Displacement Equation Of Hornmentioning

confidence: 99%

Design and Analysis of Hollow Catenoidal Horn Profile for Ultrasonic Machining of Composite Materials

Mutahir

Rehman

2022

J. Stud. Sci. Eng.

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“…The modal properties of ultrasonic horn are evaluated by solving the eigenvalue problem as follows [31,32]:…”

Section: Modal Analysis Of the Ultrasonic Hornmentioning

confidence: 99%

“…Generally, the main components of the ultrasonic treatment device are an ultrasonic generator, a transducer, an ultrasonic horn, a tool head, etc. [31,32]. The function of the transducer is to convert the electrical signal generated by the transmitter into mechanical vibration, which provides the amplitude required for the preparation of the composite materials [33,34].…”

Section: Introductionmentioning

confidence: 99%

“…However, the amplitude of vibration produced by the transducer is of order 5-10 µm, which is very low for the preparation of the composite materials [31,35]. As an important part, the ultrasonic horn, also termed as an amplifier, transformer, concentrator, or acoustic coupler, is employed to magnify the amplitude of vibration to a value suitable for the preparation of the composite materials [32,36]. In addition, the frequency of the horn is the same as the frequency of the transducer, which results in the ultrasonic vibration system reaching a resonance state.…”

Section: Introductionmentioning

confidence: 99%

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Design and Development of a Novel Ultrasonic Field Wetting Angle Measuring Instrument for Researching the Wetting of the Liquid–Solid Interface

et al. 2021

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A key technical problem in the preparation of Al-Ti-C grain refiner and other composite materials is the poor wetting of the Al-C interface, which greatly restricts the development of the preparation technology of related composite materials. In view of this scientific challenge, a novel ultrasonic field wetting angle measuring instrument has been designed to research the wetting behavior of the liquid–solid interface and ensure that preparation conditions are optimized. The dimensional parameters of the ultrasonic transducer and the horn in the novel ultrasonic wetting angle measuring instrument have been designed by theoretical calculation, and the modal analysis was performed for the ultrasonic horn using the functions of displacement and time. Modal analysis was utilized to optimize the dimension of the ultrasonic horn, and the natural frequency of the longitudinal vibration of the horn was reduced from 22,130 Hz to 22,013 Hz, resulting in an error rate between the actual value (22,013 Hz) and the design value (20 kHz) of less than 1%. In addition, the influence of different transition arc radiuses on the maximum stress of the optimized ultrasonic horn was analyzed.

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Study on Regeneration of Ultrasonic Horn for Gemstone Carving

Pham,

Nguyen,

Tran

2022

Lecture Notes in Mechanical Engineering

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Novel ultrasonic horn design for machining advanced brittle composites: A step forward towards green and sustainable manufacturing

Cited by 21 publications

References 45 publications

Design and Analysis of Hollow Catenoidal Horn Profile for Ultrasonic Machining of Composite Materials

Design and Analysis of Hollow Catenoidal Horn Profile for Ultrasonic Machining of Composite Materials

Design and Development of a Novel Ultrasonic Field Wetting Angle Measuring Instrument for Researching the Wetting of the Liquid–Solid Interface

Study on Regeneration of Ultrasonic Horn for Gemstone Carving

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