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Ultrasonic vibration micro-shaping using single PZT actuator-embedded tool holder

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Abstract

In this study, we suggest a novel tool holder design for simple and cost-effective ultrasonic vibration shaping to provide improvements such as low cutting force, smooth chip exhaust, and better surface quality in the cutting performance. An ultrasonic vibration tool actuated by a single actuator, which was designed by asymmetrically installing a single PZT actuator inside a cylindrical tool holder, generated the synchronized two-axis ultrasonic vibration motion on the tool tip along the cutting and thrust directions. By conducting dynamic structural analysis and simulating the tool tip movement trajectory using finite element method, the resonance mode, amplitude, and frequency of the model were optimized to achieve the vibration characteristics required for precision micro-shaping processes. According to the experimental evaluations, the vibration of the tool holder was characterized by a resonance mode of 24 kHz. The cutting performance of the tool was evaluated by comparing the cutting force, machined surface, and chip shape with those using a non-vibration micro-shaping tool. The cutting force was reduced more than 90 %, and the machined shape and chip exhaust were improved compared with that in conventional shaping processes.

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Acknowledgments

We would like to acknowledge the financial support from the platform R&D program of KITECH (Korea Institute of Industrial Technology) of Republic of Korea (Grant PEO20580) and National Research Foundation of Korea (NRFK) (Grant 2020R1A2C1004784).

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Authors and Affiliations

  1. Korea Institute of Industrial Technology, Bucheon, 14441, Korea

    Jongsu Kim

  2. Department of Mechanical System Design Engineering, Seoul National University of Science and Technology, Seoul, 01811, Korea

    Joohyung Lee

  3. School of Mechanical Engineering, Kookmin University, Seoul, 02707, Korea

    Bongchul Kang

Authors
  1. Jongsu Kim
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  2. Joohyung Lee
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  3. Bongchul Kang
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Corresponding author

Correspondence to Bongchul Kang.

Additional information

Bongchul Kang is an Associate Professor of the School of Mechanical Engineering at Kookmin University. He received his Ph.D. degree in Mechanical Engineering from Korea Advanced Institute of Science and Technology (KAIST), Korea. His research interests include laser-nanomaterial interactions, laser processing, ultra-precision engineering, and nontraditional manufacturing.

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Kim, J., Lee, J. & Kang, B. Ultrasonic vibration micro-shaping using single PZT actuator-embedded tool holder. J Mech Sci Technol 35, 3123–3129 (2021). https://doi.org/10.1007/s12206-021-0634-9

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  • DOI: https://doi.org/10.1007/s12206-021-0634-9

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