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Design and experimental investigation on longitudinal-torsional composite horn considering the incident angle of ultrasonic wave

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Abstract

The composite vibration mode type of ultrasonic horn has been widely employed in ultrasonic vibration drilling. In order to explore the effect of the incident angle of the ultrasonic wave on longitudinal-torsional composite (LTC) horn, the reason for the mode-conversion and the vibrational characteristics of such horn firstly were analyzed on the basis of elastic wave-field theory. Then, a 3D model was developed with helical slots with different angle set in the conical section of the composite horn, and the vibration modal of the output end face of the horn was analyzed using the finite element analysis (FEA) method. It was found that the incident angle of ultrasonic wave exhibited a significant influence on the vibration modal at the output end face of the horn. The torsional vibration and the longitudinal vibration were changed significantly at the output end face of the horn when the incident angle was 47.6° and 67.2°, and the measured amplitude ratio of the torsional vibration to the longitudinal vibration in the former was improved by 4.9 times than that in the latter. Simultaneously, in both cases, the error of resonant frequency between the measurement and the simulation value reached 1.9% and 1.3%, respectively. It was observed from the ultrasonic vibration drilling test that the higher the amplitude ratio of the torsional vibration to the longitudinal vibration (AT/AL), the more the average drilling force was reduced and the better machined quality could be obtained. The results of this study should be well considered for further reference when designing longitudinal-torsional composite horn with different materials in ultrasonic vibration drilling.

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Funding

The authors gratefully acknowledge the support of the National Natural Science Foundation of China (Grant Nos. U1604255, 51475148).

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Authors and Affiliations

  1. School of Mechanical and Power Engineering, Henan Polytechnic University, Jiaozuo, 454003, Henan, China

    Bo Zhao, Wenbo Bie, Xiaobo Wang & Baoqi Chang

  2. School of Electrical and Mechanical Engineering, Pingdingshan University, Pingdingshan, 467000, Henan, China

    Fan Chen

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  1. Bo Zhao
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  2. Wenbo Bie
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  3. Xiaobo Wang
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  4. Fan Chen
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  5. Baoqi Chang
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Correspondence to Wenbo Bie.

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Zhao, B., Bie, W., Wang, X. et al. Design and experimental investigation on longitudinal-torsional composite horn considering the incident angle of ultrasonic wave. Int J Adv Manuf Technol 105, 325–341 (2019). https://doi.org/10.1007/s00170-019-04220-0

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  • DOI: https://doi.org/10.1007/s00170-019-04220-0

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