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Design of ultrasonic elliptical vibration cutting system for tungsten heavy alloy

《机械工程前沿（英文）》 2022年 第17卷 第4期 doi: 10.1007/s11465-022-0715-1

摘要： Nanoscale surface roughness of tungsten heavy alloy components is required in the nuclear industry and precision instruments. In this study, a high-performance ultrasonic elliptical vibration cutting (UEVC) system is developed to solve the precision machining problem of tungsten heavy alloy. A new design method of stepped bending vibration horn based on Timoshenko’s theory is first proposed, and its design process is greatly simplified. The arrangement and working principle of piezoelectric transducers on the ultrasonic vibrator using the fifth resonant mode of bending are analyzed to realize the dual-bending vibration modes. A cutting tool is installed at the end of the ultrasonic vibration unit to output the ultrasonic elliptical vibration locus, which is verified by finite element method. The vibration unit can display different three-degree-of-freedom (3-DOF) UEVC characteristics by adjusting the corresponding position of the unit and workpiece. A dual-channel ultrasonic power supply is developed to excite the ultrasonic vibration unit, which makes the UEVC system present the resonant frequency of 41 kHz and the maximum amplitude of 14.2 μm. Different microtopography and surface roughness are obtained by the cutting experiments of tungsten heavy alloy hemispherical workpiece with the UEVC system, which validates the proposed design’s technical capability and provides optimization basis for further improving the machining quality of the curved surface components of tungsten heavy alloy.

关键词： tungsten heavy alloy     ultrasonic elliptical vibration cutting     Timoshenko’s theory     resonant mode of bending     finite element method    

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Postprocessor development for ultrasonic cutting of honeycomb core curved surface with a straight blade

《机械工程前沿（英文）》 2023年 第18卷 第1期 doi: 10.1007/s11465-022-0729-8

摘要： When ultrasonically cutting honeycomb core curved parts, the tool face of the straight blade must be along the curved surface’s tangent direction at all times to ensure high-quality machining of the curved surface. However, given that the straight blade is a nonstandard tool, the existing computer-aided manufacturing technology cannot directly realize the above action requirement. To solve this problem, this paper proposed an algorithm for extracting a straight blade real-time tool face vector from a 5-axis milling automatically programmed tool location file, which can realize the tool location point and tool axis vector conversion from the flat end mill to the straight blade. At the same time, for the multi-solution problem of the rotation axis, the dependent axis rotation minimization algorithm was introduced, and the spindle rotation algorithm was proposed for the tool edge orientation problem when the straight blade is used to machine the curved part. Finally, on the basis of the MATLAB platform, the dependent axis rotation minimization algorithm and spindle rotation algorithm were integrated and compiled, and the straight blade ultrasonic cutting honeycomb core postprocessor was then developed. The model of the machine tool and the definition of the straight blade were conducted in the VERICUT simulation software, and the simulation machining of the equivalent entity of the honeycomb core can then be realized. The correctness of the numerical control program generated by the postprocessor was verified by machining and accuracy testing of the two designed features. Observation and analysis of the simulation and experiment indicate that the tool pose is the same under each working condition, and the workpieces obtained by machining also meet the corresponding accuracy requirements. Therefore, the postprocessor developed in this paper can be well adapted to the honeycomb core ultrasonic cutting machine tool and realize high-quality and high-efficient machining of honeycomb core composites.

关键词： honeycomb core     straight blade     ultrasonic cutting     tool pose     postprocessor    

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Vibration characteristics and machining performance of a novel perforated ultrasonic vibration platform

《机械工程前沿（英文）》 2023年 第18卷 第1期 doi: 10.1007/s11465-022-0730-2

摘要： Ultrasonic vibration-assisted grinding (UVAG) is an advanced hybrid process for the precision machining of difficult-to-cut materials. The resonator is a critical part of the UVAG system. Its performance considerably influences the vibration amplitude and resonant frequency. In this work, a novel perforated ultrasonic vibration platform resonator was developed for UVAG. The holes were evenly arranged at the top and side surfaces of the vibration platform to improve the vibration characteristics. A modified apparent elasticity method (AEM) was proposed to reveal the influence of holes on the vibration mode. The performance of the vibration platform was evaluated by the vibration tests and UVAG experiments of particulate-reinforced titanium matrix composites. Results indicate that the reasonable distribution of holes helps improve the resonant frequency and vibration mode. The modified AEM, the finite element method, and the vibration tests show a high degree of consistency for developing the perforated ultrasonic vibration platform with a maximum frequency error of 3%. The employment of ultrasonic vibration reduces the grinding force by 36% at most, thereby decreasing the machined surface defects, such as voids, cracks, and burnout.

关键词： ultrasonic vibration-assisted grinding     perforated ultrasonic vibration platform     vibration characteristics     apparent elasticity method     grinding force     surface integrity    

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Machinability of ultrasonic vibration-assisted micro-grinding in biological bone using nanolubricant

《机械工程前沿（英文）》 2023年 第18卷 第1期 doi: 10.1007/s11465-022-0717-z

摘要： Bone grinding is an essential and vital procedure in most surgical operations. Currently, the insufficient cooling capacity of dry grinding, poor visibility of drip irrigation surgery area, and large grinding force leading to high grinding temperature are the technical bottlenecks of micro-grinding. A new micro-grinding process called ultrasonic vibration-assisted nanoparticle jet mist cooling (U-NJMC) is innovatively proposed to solve the technical problem. It combines the advantages of ultrasonic vibration (UV) and nanoparticle jet mist cooling (NJMC). Notwithstanding, the combined effect of multi parameter collaborative of U-NJMC on cooling has not been investigated. The grinding force, friction coefficient, specific grinding energy, and grinding temperature under dry, drip irrigation, UV, minimum quantity lubrication (MQL), NJMC, and U-NJMC micro-grinding were compared and analyzed. Results showed that the minimum normal grinding force and tangential grinding force of U-NJMC micro-grinding were 1.39 and 0.32 N, which were 75.1% and 82.9% less than those in dry grinding, respectively. The minimum friction coefficient and specific grinding energy were achieved using U-NJMC. Compared with dry, drip, UV, MQL, and NJMC grinding, the friction coefficient of U-NJMC was decreased by 31.3%, 17.0%, 19.0%, 9.8%, and 12.5%, respectively, and the specific grinding energy was decreased by 83.0%, 72.7%, 77.8%, 52.3%, and 64.7%, respectively. Compared with UV or NJMC alone, the grinding temperature of U-NJMC was decreased by 33.5% and 10.0%, respectively. These results showed that U-NJMC provides a novel approach for clinical surgical micro-grinding of biological bone.

关键词： micro-grinding     biological bone     ultrasonic vibration (UV)     nanoparticle jet mist cooling (NJMC)     grinding force     grinding temperature    

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Effects of inclination angles of disc cutter on machining quality of Nomex honeycomb core in ultrasoniccutting

Yidan WANG, Renke KANG, Yan QIN, Qian MENG, Zhigang DONG

《机械工程前沿（英文）》 2021年 第16卷 第2期   页码 285-297 doi: 10.1007/s11465-021-0631-9

摘要： Ultrasonic cutting with a disc cutter is an advanced machining method for the high-quality processing of Nomex honeycomb core. The machining quality is influenced by ultrasonic cutting parameters, as well as tool orientations, which are determined by the multi-axis machining requirements and the angle control of the cutting system. However, in existing research, the effect of the disc cutter orientation on the machining quality has not been studied in depth, and practical guidance for the use of disc cutters is lacking. In this work, the inclined ultrasonic cutting process with a disc cutter was analyzed, and cutting experiments with different inclination angles were conducted. The theoretical residual height models of the honeycomb core, as a result of the lead and tilt angles, were established and verified with the results obtained by a linear laser displacement sensor. Research shows that the residual height of the honeycomb core, as a result of the tilt angle, is much larger than that as a result of the lead angle. Furthermore, the tearing of the cell wall on the machined surface was observed, and the effects of the ultrasonic vibration, lead angle, and tilt angle on the tear rate and tear length of the cell wall were studied. Experimental results revealed that ultrasonic vibration can effectively decrease the tearing of the cell wall and improve the machining quality. Changes in the tilt angle have less effect than changes in the lead angle on the tearing of the cell wall. The determination of inclination angles should consider the actual processing requirements for the residual height and the machining quality of the cell wall. This study investigates the influence of the inclination angles of a disc cutter on the machining quality of Nomex honeycomb core in ultrasonic cutting and provides guidelines for machining.

关键词： Nomex honeycomb core     disc cutter     inclined ultrasonic cutting     machining quality    

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Detection of solder bump defects on a flip chip using vibration analysis

Junchao LIU, Tielin SHI, Qi XIA, Guanglan LIAO

《机械工程前沿（英文）》 2012年 第7卷 第1期   页码 29-37 doi: 10.1007/s11465-012-0314-7

摘要：

Flip chips are widely used in microelectronics packaging owing to the high demand of integration in IC fabrication. Solder bump defects on flip chips are difficult to detect, because the solder bumps are obscured by the chip and substrate. In this paper a nondestructive detection method combining ultrasonic excitation with vibration analysis is presented for detecting missing solder bumps, which is a typical defect in flip chip packaging. The flip chip analytical model is revised by considering the influence of spring mass on mechanical energy of the system. This revised model is then applied to estimate the flip chip resonance frequencies. We use an integrated signal generator and power amplifier together with an air-coupled ultrasonic transducer to excite the flip chips. The vibrations are measured by a laser scanning vibrometer to detect the resonance frequencies. A sensitivity coefficient is proposed to select the sensitive resonance frequency order for defect detection. Finite element simulation is also implemented for further investigation. The results of analytical computation, experiment, and simulation prove the efficacy of the revised flip chip analytical model and verify the effectiveness of this detection method. Therefore, it may provide a guide for the improvement and innovation of the flip chip on-line inspection systems.

关键词： flip chip     defect detection     ultrasonic excitation     vibration analysis    

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Hole quality in longitudinal–torsional coupled ultrasonic vibration assisted drilling of carbon fiber

Guofeng MA, Renke KANG, Zhigang DONG, Sen YIN, Yan BAO, Dongming GUO

《机械工程前沿（英文）》 2020年 第15卷 第4期   页码 538-546 doi: 10.1007/s11465-020-0598-y

摘要： Carbon fiber reinforced plastic (CFRP) composites are extremely attractive in the manufacturing of structural and functional components in the aircraft manufacturing field due to their outstanding properties, such as good fatigue resistance, high specific stiffness/strength, and good shock absorption. However, because of their inherent anisotropy, low interlamination strength, and abrasive characteristics, CFRP composites are considered difficult-to-cut materials and are prone to generating serious hole defects, such as delamination, tearing, and burrs. The advanced longitudinal–torsional coupled ultrasonic vibration assisted drilling (LTC-UAD) method has a potential application for drilling CFRP composites. At present, LTC-UAD is mainly adopted for drilling metal materials and rarely for CFRP. Therefore, this study analyzes the kinematic characteristics and the influence of feed rate on the drilling performance of LTC-UAD. Experimental results indicate that LTC-UAD can reduce the thrust force by 39% compared to conventional drilling. Furthermore, LTC-UAD can decrease the delamination and burr factors and improve the surface quality of the hole wall. Thus, LTC-UAD is an applicable process method for drilling components made with CFRP composites.

关键词： longitudinal–torsional coupled     ultrasonically drilling     CFRP     thrust force     hole quality    

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Ultrasonic linear motor using the L-B mode Langevin transducer with an exponential horn

SHI Shengjun, CHEN Weishan, LIU Junkao, ZHAO Xuetao

《机械工程前沿（英文）》 2008年 第3卷 第2期   页码 212-217 doi: 10.1007/s11465-008-0026-1

摘要： An ultrasonic linear motor is proposed and fabricated by using the longitudinal and bending vibration double mode bolt-clamped Langevin type transducer to meet high power and speed requirements in the aerospace and semiconductor ind

关键词： longitudinal     vibration     bolt-clamped     semiconductor     ultrasonic    

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Ultrasonic assisted EDM: Effect of the workpiece vibration in the machining characteristics of FW4 Welded

Mohammadreza SHABGARD, Hamed KAKOLVAND, Mirsadegh SEYEDZAVVAR, Ramin Mohammadpour SHOTORBANI

《机械工程前沿（英文）》 2011年 第6卷 第4期   页码 419-428 doi: 10.1007/s11465-011-0246-7

摘要：

This paper presents the results of experimental studies carried out to conduct a comprehensive investigation on the influence of ultrasonic vibration of workpiece on the characteristics of Electrical Discharge Machining (EDM) process of FW4 Welding Metal in comparison with the conventional EDM process. The studied process characteristics included the material removal rate (MRR), tool wear ratio (TWR), and surface roughness (Ra and Rmax) of the workpiece after the EDM and ultrasonic assisted EDM (US-EDM) processes. The experiments performed under the designed full factorial procedure and the considered EDM input parameters included pulse on-time and pulse current. The experimental results show that in short pulse on-times, material removal rate in the US-EDM process is approximately quadruple than that of the EDM process. On the contrary, in the long pulse on-times, ultrasonic vibration of work??piece leads to the reduction in the MRR. On the other hand, in short pulse on-times, the TWR in the US-EDM process is lower than that of in the EDM process, and this condition reverses with increase in the pulse on-time. Furthermore, the surface roughness of the workpiece machined by EDM process is slightly lower than that of applied to the US-EDM process.

关键词： electrical discharge machining (EDM)     material removal rate (MRR)     tool wear ratio (TWR)     surface roughness    

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Piezocatalytic performance of FeO−BiMoO catalyst for dye degradation

《化学科学与工程前沿（英文）》 2023年 第17卷 第6期   页码 716-725 doi: 10.1007/s11705-022-2265-9

摘要： A Fe2O3−Bi2MoO6 heterojunction was synthesized via a hydrothermal method. Scanning electron microscopy, transmission electron microscopy, energy-dispersive X-ray, powder X-ray diffraction, Fourier transform infrared spectroscopy and ultra-violet−visible near-infrared spectrometry were performed to measure the structures, morphologies and optical properties of the as-prepared samples. The various factors that affected the piezocatalytic property of composite catalyst were studied. The highest rhodamine B degradation rate of 96.6% was attained on the 3% Fe2O3−Bi2MoO6 composite catalyst under 60 min of ultrasonic vibration. The good piezocatalytic activity was ascribed to the formation of a hierarchical flower-shaped microsphere structure and the heterostructure between Fe2O3 and Bi2MoO6, which effectively separated the ultrasound-induced electron–hole pairs and suppressed their recombination. Furthermore, a potential piezoelectric catalytic dye degradation mechanism of the Fe2O3−Bi2MoO6 catalyst was proposed based on the band potential and quenching effect of radical scavengers. The results demonstrated the potential of using Fe2O3−Bi2MoO6 nanocomposites in piezocatalytic applications.

关键词： piezocatalysis     Fe2O3−Bi2MoO6     dye decomposition     ultrasonic vibration    

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Fracture behavior of two non-symmetrical collinear cracks emanating from an elliptical hole in a piezoelectric

Junhong GUO, Zixing LU

《机械工程前沿（英文）》 2011年 第6卷 第3期   页码 296-300 doi: 10.1007/s11465-011-0236-9

摘要：

Based on the Stroh-type formalism and the technique of conformal mapping, the problem of two non-symmetrical collinear cracks emanating from an elliptical hole in a piezoelectric solid is investigated under remotely uniform in-plane electric loading and anti-plane mechanical loading, which allowed us to take the electric field inside the hole and cracks into account. The analytical solutions of the field intensity factors and the energy release rate are presented in closed-form, which includes the extreme cases for an impermeable crack and a permeable crack. Numerical results are then presented to reveal the effects of geometrical parameters, crack permeability and combined mechanical and electric loadings on the energy release rate.

关键词： piezoelectric materials     elliptical hole     semi-permeable crack     energy release rate     analytic solution    

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Static and dynamic analysis of functionally graded fluid-infiltrated porous skew and elliptical nanoplates

《结构与土木工程前沿（英文）》 2023年 第17卷 第3期   页码 477-502 doi: 10.1007/s11709-023-0918-5

摘要： The analysis of static bending and free and forced vibration responses of functionally graded fluid-infiltrated porous (FGFP) skew and elliptical nanoplates placed on Pasternak’s two-parameter elastic foundation is performed for the first time using isogeometric analysis (IGA) based on the non-uniform rational B-splines (NURBSs) basis function. Three types of porosity distributions affect the mechanical characteristics of materials: symmetric distribution, upper asymmetric distribution, and lower asymmetric distribution. The stress–strain relationship for Biot porous materials was determined using the elastic theory. The general equations of motion of the nanoplates were established using the four-unknown shear deformation plate theory in conjunction with the nonlocal elastic theory and Hamilton’s principle. A computer program that uses IGA to determine the static bending and free and forced vibration of a nanoplate was developed on MATLAB software platform. The accuracy of the computational program was validated via numerical comparison with confidence assertions. This set of programs presents the influence of the following parameters on the static bending and free and forced vibrations of nanoplates: porosity distribution law, porosity coefficient and geometrical parameters, elastic foundation, deviation angle, nonlocal coefficient, different boundary conditions, and Skempton coefficients. The numerical findings demonstrated the uniqueness of the FGFP plate’s behavior when the porosities are saturated with liquid compared with the case without liquid. The findings of this study have significant implications for engineers involved in the design and fabrication of the aforementioned type of structures. Furthermore, this can form the basis for future research on the mechanical responses of the structures.

关键词： static bending     free and forced vibrations     nonlocal theory     isogeometric analysis     fluid-infiltrated porous nanoplates    

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Elliptical lobe shape gerotor pump design to minimize wear

Mohammad Reza KARAMOOZ RAVARI

《机械工程前沿（英文）》 2011年 第6卷 第4期   页码 429-434 doi: 10.1007/s11465-011-0247-6

摘要：

The gerotor pumps are the most important parts of mechanical equipment that have a vast number of applications in industries and automobiles. Because the gerotor pumps cannot be adjusted for wear so it is important to reduce the wear as much as possible. In this paper first mathematical equations for elliptical lobe shape rotors profile and curvature of them have been derived and then Specific flow and wear rate proportional factor (WRPF) have been formulated. To reach the minimum wear in rotors teeth, the ellipse shape factor is changed for each value of number of outer rotor teeth in a feasible range and wear rate proportional factor has been resulted. Also in order to have better comparison specific flow has been presented. The obtained results have been compared with circular pumps with similar geometrical parameters and show the significant improvement in wear of the rotors with negligible changes in the specific flow.

关键词： gerotor pump     elliptical lobe shape pump     wear rate proportional factor (WRPF)     specific flow    

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density measurement for plastic injection molding via ultrasonic technology

《机械工程前沿（英文）》 2022年 第17卷 第4期 doi: 10.1007/s11465-022-0714-2

摘要： Density variation during the injection molding process directly reflects the state of plastic melt and contains valuable information for process monitoring and optimization. Therefore, in-situ density measurement is of great interest and has significant application value. The existing methods, such as pressure−volume−temperature (PVT) method, have the shortages of time-delay and high cost of sensors. This study is the first to propose an in-situ density measurement method using ultrasonic technology. The analyses of the time-domain and frequency-domain signals are combined in the proposed method. The ultrasonic velocity is obtained from the time-domain signals, and the acoustic impedance is computed through a full-spectral analysis of the frequency-domain signals. Experiments with different process conditions are conducted, including different melt temperature, injection speed, material, and mold structure. Results show that the proposed method has good agreement with the PVT method. The proposed method has the advantages of in-situ measurement, non-destructive, high accuracy, low cost, and is of great application value for the injection molding industry.

关键词： ultrasonic measurement     melt density     in-situ measurement     injection molding    

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Crystallographic orientation effect on cutting-based single atomic layer removal

Wenkun XIE, Fengzhou FANG

《机械工程前沿（英文）》 2020年 第15卷 第4期   页码 631-644 doi: 10.1007/s11465-020-0599-x

摘要： The ever-increasing requirements for the scalable manufacturing of atomic-scale devices emphasize the significance of developing atomic-scale manufacturing technology. The mechanism of a single atomic layer removal in cutting is the key basic theoretical foundation for atomic-scale mechanical cutting. Material anisotropy is among the key decisive factors that could not be neglected in cutting at such a scale. In the present study, the crystallographic orientation effect on the cutting-based single atomic layer removal of monocrystalline copper is investigated by molecular dynamics simulation. When undeformed chip thickness is in the atomic scale, two kinds of single atomic layer removal mechanisms exist in cutting-based single atomic layer removal, namely, dislocation motion and extrusion, due to the differing atomic structures on different crystallographic planes. On close-packed crystallographic plane, the material removal is dominated by the shear stress-driven dislocation motion, whereas on non-close packed crystallographic planes, extrusion-dominated material removal dominates. To obtain an atomic, defect-free processed surface, the cutting needs to be conducted on the close-packed crystallographic planes of monocrystalline copper.

关键词： ACSM     single atomic layer removal mechanism     crystallographic orientation effect     mechanical cutting     Manufacturing III    

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标题 作者 时间 类型 操作

Design of ultrasonic elliptical vibration cutting system for tungsten heavy alloy

期刊论文

Postprocessor development for ultrasonic cutting of honeycomb core curved surface with a straight blade

期刊论文

Vibration characteristics and machining performance of a novel perforated ultrasonic vibration platform

期刊论文

Machinability of ultrasonic vibration-assisted micro-grinding in biological bone using nanolubricant

期刊论文

Effects of inclination angles of disc cutter on machining quality of Nomex honeycomb core in ultrasoniccutting

Yidan WANG, Renke KANG, Yan QIN, Qian MENG, Zhigang DONG

期刊论文

Detection of solder bump defects on a flip chip using vibration analysis

Junchao LIU, Tielin SHI, Qi XIA, Guanglan LIAO

期刊论文

Hole quality in longitudinal–torsional coupled ultrasonic vibration assisted drilling of carbon fiber

Guofeng MA, Renke KANG, Zhigang DONG, Sen YIN, Yan BAO, Dongming GUO

期刊论文

Ultrasonic linear motor using the L-B mode Langevin transducer with an exponential horn

SHI Shengjun, CHEN Weishan, LIU Junkao, ZHAO Xuetao

期刊论文

Ultrasonic assisted EDM: Effect of the workpiece vibration in the machining characteristics of FW4 Welded

Mohammadreza SHABGARD, Hamed KAKOLVAND, Mirsadegh SEYEDZAVVAR, Ramin Mohammadpour SHOTORBANI

期刊论文

Piezocatalytic performance of FeO−BiMoO catalyst for dye degradation

期刊论文

Fracture behavior of two non-symmetrical collinear cracks emanating from an elliptical hole in a piezoelectric

Junhong GUO, Zixing LU

期刊论文

Static and dynamic analysis of functionally graded fluid-infiltrated porous skew and elliptical nanoplates

期刊论文

Elliptical lobe shape gerotor pump design to minimize wear

Mohammad Reza KARAMOOZ RAVARI

期刊论文

density measurement for plastic injection molding via ultrasonic technology

期刊论文

Crystallographic orientation effect on cutting-based single atomic layer removal

Wenkun XIE, Fengzhou FANG

期刊论文