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On-line Access: 2024-04-16

Received: 2023-05-04

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Crosschecked: 2024-04-16

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 ORCID:

Tae Jo KO

https://orcid.org/0000-0003-1465-696X

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Journal of Zhejiang University SCIENCE A 2024 Vol.25 No.4 P.292-310

http://doi.org/10.1631/jzus.A2300243


Influence of overhanging tool length and vibrator material on electromechanical impedance and amplitude prediction in ultrasonic spindle vibrator


Author(s):  Rendi KURNIAWAN, Moran XU, Min Ki CHOO, Shuo CHEN, Yein KWAK, Jielin CHEN, Saood ALI, Hanwei TENG, Pil Wan HAN, Gi Soo KIM, Tae Jo KO

Affiliation(s):  Precision Machining Laboratory, Department of Mechanical Engineering, Yeungnam University, Gyeongsan-si, Gyeongbuk-do, Republic of Korea; more

Corresponding email(s):   pwhan@keri.re.kr, tjko@yu.ac.kr

Key Words:  Ultrasonic spindle, Ultrasonic vibration assisted-milling (UVAM), 1-degree of freedom (DOF), Frequency, Amplitude, Milling


Rendi KURNIAWAN, Moran XU, Min Ki CHOO, Shuo CHEN, Yein KWAK, Jielin CHEN, Saood ALI, Hanwei TENG, Pil Wan HAN, Gi Soo KIM, Tae Jo KO. Influence of overhanging tool length and vibrator material on electromechanical impedance and amplitude prediction in ultrasonic spindle vibrator[J]. Journal of Zhejiang University Science A, 2024, 25(4): 292-310.

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author="Rendi KURNIAWAN, Moran XU, Min Ki CHOO, Shuo CHEN, Yein KWAK, Jielin CHEN, Saood ALI, Hanwei TENG, Pil Wan HAN, Gi Soo KIM, Tae Jo KO",
journal="Journal of Zhejiang University Science A",
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number="4",
pages="292-310",
year="2024",
publisher="Zhejiang University Press & Springer",
doi="10.1631/jzus.A2300243"
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%A Moran XU
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%A Jielin CHEN
%A Saood ALI
%A Hanwei TENG
%A Pil Wan HAN
%A Gi Soo KIM
%A Tae Jo KO
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A1 - Rendi KURNIAWAN
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A1 - Shuo CHEN
A1 - Yein KWAK
A1 - Jielin CHEN
A1 - Saood ALI
A1 - Hanwei TENG
A1 - Pil Wan HAN
A1 - Gi Soo KIM
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PB - Zhejiang University Press & Springer
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DOI - 10.1631/jzus.A2300243


Abstract: 
This study presents the development of an ultrasonic transducer with a radius horn for an ultrasonic milling spindle (UMS) system. The ultrasonic transducer was intended to have a working frequency of approximately 30 kHz. Two different materials were considered in the study: stainless steel (SS 316L) and titanium alloy (Ti-6Al-4V). Titanium alloy gave a higher resonance frequency (33 kHz) than stainless steel (30 kHz) under the same preload compression stress. An electromechanical impedance simulation was carried out to predict the impedance resonance frequency for both materials, and the effect of the overhanging toolbar was investigated. According to the electromechanical impedance simulation, the overhanging toolbar length affected the resonance frequency, and the error was less than 3%. Harmonic analysis confirmed that the damping ratio helps determine the resonance amplitude. Therefore, damping ratios of 0.015–0.020 and 0.005–0.020 were selected for stainless steel and titanium alloy, respectively, with an error of less than 1.5%. Experimental machining was also performed to assess the feasibility of ultrasonic-assisted milling; the result was a lesser cutting force and better surface topography of Al 6061.

刀具悬伸长度和换能器材料对超声主轴振动器的机电阻抗和振幅预测的影响

作者:Rendi KURNIAWAN1,Moran XU1, Min Ki CHOO1, Shuo CHEN1, Yein KWAK1, Jielin CHEN1, Saood ALI1, Hanwei TENG1, Pin WanHAN2, Gi Soo KIM3, Tae Jo KO1
机构:1Precision Machining Laboratory, Department of Mechanical Engineering, Yeungnam University, Gyeongsan-si, Gyeongbuk-do, Republic of Korea;2Korea Electrotechnology Research Institute (KERI), Changwon-si, Gyeongsangnam-do, Republic of Korea;3KASWIN Co., Ltd, Changwon-si, Gyeongsangnam-do, Republic of Korea
目的:本文围绕用于设计单自由度谐振装备的阻抗频率和振幅预测展开研究,并考虑刀具悬伸长度(OL)和换能器不同材料的影响。此外,本文旨在提出一种考虑OL和不同材料影响的阻抗和阻尼比模型,以预测谐振频率和振幅。
创新点:1.在阻抗模型中将圆角形变幅杆简化为指数形,并简化夹头、螺母和刀具。2.在振幅仿真分析中考虑振幅与阻尼比的关系,以精确预测振幅。3.在实验验证中研究换能器不同材料的影响。
方法:1.选用不锈钢(SS 316L)和钛合金(Ti-6Al-4V)做为超声换能器的材料,并在超声换能器上施加最大可达20 MPa的预紧力。2.研究OL在40~50 mm范围内变化时对谐振频率的影响,并测量在100~300 V电压下的谐振振幅。3.进行铝合金6061铣削实验以验证超声换能器的性能。
结论:1.钛合金材料具有较高的谐振频率和最大25.6 μm的振幅。2.机电阻抗仿真预测谐振频率的误差小于3%。3.为了准确预测谐振振幅,有必要通过标定校准来确定阻尼比。4.加工可行性实验表明,超声换能器可以使切削力降低20%~30%。

关键词:超声主轴;超声振动辅助铣削;单自由度;频率;振幅;铣削

Darkslateblue:Affiliate; Royal Blue:Author; Turquoise:Article

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