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Influence of overhanging tool length and vibrator material on electromechanical impedance and amplitude prediction in ultrasonic spindle vibrator
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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.
@article{title="Influence of overhanging tool length and vibrator material on electromechanical impedance and amplitude prediction in ultrasonic spindle vibrator",
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",
volume="25",
number="4",
pages="292-310",
year="2024",
publisher="Zhejiang University Press & Springer",
doi="10.1631/jzus.A2300243"
}
%0 Journal Article
%T Influence of overhanging tool length and vibrator material on electromechanical impedance and amplitude prediction in ultrasonic spindle vibrator
%A Rendi KURNIAWAN
%A Moran XU
%A Min Ki CHOO
%A Shuo CHEN
%A Yein KWAK
%A Jielin CHEN
%A Saood ALI
%A Hanwei TENG
%A Pil Wan HAN
%A Gi Soo KIM
%A Tae Jo KO
%J Journal of Zhejiang University SCIENCE A
%V 25
%N 4
%P 292-310
%@ 1673-565X
%D 2024
%I Zhejiang University Press & Springer
%DOI 10.1631/jzus.A2300243
TY - JOUR
T1 - Influence of overhanging tool length and vibrator material on electromechanical impedance and amplitude prediction in ultrasonic spindle vibrator
A1 - Rendi KURNIAWAN
A1 - Moran XU
A1 - Min Ki CHOO
A1 - Shuo CHEN
A1 - Yein KWAK
A1 - Jielin CHEN
A1 - Saood ALI
A1 - Hanwei TENG
A1 - Pil Wan HAN
A1 - Gi Soo KIM
A1 - Tae Jo KO
J0 - Journal of Zhejiang University Science A
VL - 25
IS - 4
SP - 292
EP - 310
%@ 1673-565X
Y1 - 2024
PB - Zhejiang University Press & Springer
ER -
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.
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