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Design of a novel integrated ultrasonic tool holder for friction stir welding

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Abstract

Ultrasonic vibration friction stir welding (UVFSW) has shown advantages in reducing welding defects and improving welding quality in aerospace, automobile, and power electronics. In this study, we design a novel 20-kHz integrated ultrasonic tool holder in FSW. The finite element model of FSW transducer is established, where the elastic modulus is measured by non-destructive acoustic. In the three transducer prototypes with alloy steel, the effect of prestress on resonant frequency is investigated and the ultrasonic vibration is measured. It proves that the resonant frequencies are well consistent between simulation model and the experiment by the elastic modulus testing and the prestress optimization. The ultrasonic amplitude of the pin is up to 24 μm. The experiment also indicates that the vibration is different with the steel material properties. Our findings can have a guidance to the design for a general ultrasonic actuator. The integrated FSW ultrasonic tool has potential to apply in a confined space in general machining equipment.

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Acknowledgements

The authors would like to appreciate the anonymous reviewers and the editor for their valuable comments.

Funding

This work is supported by the Key Research and Development Program of Guangdong Province (2020B0 90926001), the National Natural Science Foundation of China (U1913215, 2175392), the National Major Scientific Research Instrument Development of China (51827811), the Basic Research Plan of Shenzhen (JCYJ20200109113429208, JCYJ20200109112803851), and the University Stability Support Program of Shenzhen (GXWD20201230155427003-20 200824171126002).

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Authors and Affiliations

  1. Department of Mechanical Engineering and Automation, Harbin Institute of Technology (Shenzhen), Shenzhen, 518055, China

    Ju Jianzhong, Long Zhili, Ye Shuyuan, Liu Yongzhi & Zhao Heng

Authors
  1. Ju Jianzhong
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  2. Long Zhili
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  3. Ye Shuyuan
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  4. Liu Yongzhi
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  5. Zhao Heng
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Contributions

Ju Jianzhong: calculation, simulation, experiment validation, writing-original draft preparation. Long Zhili: conceptualization, supervision, funding acquisition. Ye Shuyuan: hardware system design, writing-review and editing. Liu Yongzhi: data collection, writing-review and editing. Zhao Heng: experiment testing, writing-review and editing.

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Correspondence to Long Zhili.

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Jianzhong, J., Zhili, L., Shuyuan, Y. et al. Design of a novel integrated ultrasonic tool holder for friction stir welding. Int J Adv Manuf Technol 120, 5921–5932 (2022). https://doi.org/10.1007/s00170-022-09136-w

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  • DOI: https://doi.org/10.1007/s00170-022-09136-w

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