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Experimental and analytical study of ultrasonic elliptical vibration cutting of micro-pyramid reflective mold based on guided wave transmission

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Abstract

The ultrasonic elliptical vibration cutting (UEVC) technique has been found to be a promising technique for ultra-precision machining of microstructural functional surfaces. However, the current UEVC technique can not achieve higher frequency ultrasonic cutting due to its rigid orthogonal vibration transmission. To further study the characteristics in high-frequency UEVC of microstructural surface, the UEVC based on flexible guided wave transmission is proposed which can achieve 96.8 kHz. The influence of bending vibration of guided wave band on longitudinal vibration is elaborated with the model of the bending vibration dynamic model of the guided wave. The model of elliptical trajectory deflection of tool tip is established. Based on the theoretical modeling and finite element simulation, the residual height and material removal characteristics of elliptic trajectory with variable deflection angle are simulated and analyzed. The results show that when the deflection angle is between 10∘ and 70∘, the tangential force is small and stable. Finally, the cutting experiments of micro-pyramid reflective mold in guided wave UEVC and conventional cutting (CC) are carried out. Compared with CC, high-frequency UEVC can obtain micro-pyramid elements with average roughness of 5.21 nm, which verifies the applicability of high-frequency UEVC in precision machining of microstructure.

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Acknowledgements

The authors would like to thank Mr. Yu’an Jiang for his contribution to the disposal data and experiment advice. The authors would also like to acknowledge the editors and the anonymous referees for their insightful comments.

Funding

This research was funded by Natural Science Foundation of Fujian Province (No. 2019J01327), Educational Research Projects of Young and Middle-Aged Teachers of Fujian Province (No. JAT200251) and National Natural Science Foundation Cultivation Program of Jimei University (No. ZP2020048).

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Authors and Affiliations

  1. College of Mechanical and Energy Engineering, Jimei University, No. 9 Shigu Road, Xiamen, Fujian Province, China

    Tao Jiang, Jintao Yang, Jun Pi, Wenyu Luo & Jun Zhang

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  1. Tao Jiang
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  3. Jun Pi
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Correspondence to Tao Jiang.

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Author contribution

Tao Jiang: methodology, formal analysis, writing—original draft. Jintao Yang: data curation, validation. Jun Pi: conceptualization, funding acquisition. Wenyu Luo: visualization, software. Jun Zhang: writing—review and editing, resources.

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Jiang, T., Yang, J., Pi, J. et al. Experimental and analytical study of ultrasonic elliptical vibration cutting of micro-pyramid reflective mold based on guided wave transmission. Int J Adv Manuf Technol 118, 237–253 (2022). https://doi.org/10.1007/s00170-021-07872-z

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