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Design optimization of ultrasonic vibration cutting tool to generate well-decoupled elliptical trajectory

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Abstract

Ultrasonic elliptical vibration cutting (UEVC) is a superior machining method for difficult-to-cut materials. The shape of the elliptical tool trajectory crucially affects the integrity of the machined surface. However, the existing designs of UEVC tool typically suffer from difficult motion decoupling, resulting in the low controllability of elliptical trajectory. This study presents a new optimization design method of UEVC tool with dual longitudinal generators to create well-decoupled elliptical trajectory. A theoretical model which establishes the effects of key design variables on the tool resonant characteristics was adopted to optimize the configuration angle (the included angle of two longitudinal generators) as 90°. The structural parameters of the connection blocks of the two generators were also optimized to achieve resonance matching in both the normal (depth-of-cut) and tangential (cutting) directions. The optimized tool has a stable resonant frequency of 18 kHz, a working space of 5.1 μm × 5.3 μm, and a small trajectory error of less than 0.75 μm. The vibration measurement results showed that the optimized design can enable the high controllability of tool trajectory. Grooving experiments were conducted to verify the improved cutting performance of the designed tool due to the excellent control of tool trajectory.

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The data used or analyzed in the study are available from the corresponding author on reasonable request.

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There is no program or software related code setting in this study.

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Funding

The authors gratefully acknowledge the financial support for this research provided by the Shenzhen Basic Research Discipline Layout Project of China (Subject Layout) (Grant No. JCYJ20160428181916222) and National Natural Science Foundation of China (Grant No. 51875311 and 52105458).

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Authors and Affiliations

  1. Department of Mechanical Engineering, Tsinghua University, Beijing, 100084, China

    Jinchuan Yang, Pingfa Feng, Jianfu Zhang & Jianjian Wang

  2. Division of Advanced Manufacturing, Tsinghua Shenzhen International Graduate School, Tsinghua University, Shenzhen, 518029, China

    Pingfa Feng

  3. State Key Laboratory of Tribology, Department of Mechanical Engineering, Tsinghua University, Beijing, 100084, China

    Jianfu Zhang & Jianjian Wang

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  1. Jinchuan Yang
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  2. Pingfa Feng
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Correspondence to Jianjian Wang.

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Yang, J., Feng, P., Zhang, J. et al. Design optimization of ultrasonic vibration cutting tool to generate well-decoupled elliptical trajectory. Int J Adv Manuf Technol 119, 7199–7214 (2022). https://doi.org/10.1007/s00170-022-08745-9

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  • DOI: https://doi.org/10.1007/s00170-022-08745-9

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