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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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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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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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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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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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Linear ultrasonic motor using quadrate plate transducer

Jiamei JIN, Chunsheng ZHAO

《机械工程前沿（英文）》 2009年 第4卷 第1期   页码 88-91 doi: 10.1007/s11465-009-0016-y

摘要： A linear ultrasonic motor using a quadrate plate transducer was developed for precision positioning. This motor consists of two pairs of Pb(Zr,Ti)O piezoelectric ceramic elements, which are piezoelectrically excited into the second-bending mode of the motor stator’s neutral surface in two orthogonal directions, on which the tops of four projections move along an elliptical trajectory, which in turn drives a contacted slider into linear motion via frictional forces. The coincident frequency of the stator is easily obtained for its coincident characteristic dimension in two orthogonal directions. The performance characteristics achieved by the motor are: 1) a maximum linear speed of more than 60 mm/s; 2) a stroke of more than150 mm; 3) a driving force of more than 5.0 N; and 4) a response time of about 2 ms.

关键词： ultrasonic motor     quadrate plate     coincident frequency     alternant contact    

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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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Improving the performances of ultrasonic motors using intermittent contact scheme

Jiamei JIN, Jianhui ZHANG, Fu QIAN, Zhenfeng PAN,

《机械工程前沿（英文）》 2010年 第5卷 第2期   页码 242-246 doi: 10.1007/s11465-010-0016-y

摘要： Most ultrasonic motors operate in intermittent contact scheme. Their stators drive the rotors (or sliders) when the stators contact the rotors, and the rotors (or sliders) move under an inertia force when the stators and the rotors are separated. The duty cycle of the contact and the “flight” manages motors’ output performance. To obtain a large output force or output velocity, this paper proposes a concept using the alternative work of a multi-stator or the multi-driving end of a single stator. The method can avoid larger noise, poor efficiency, and lifetime of motors. A novel linear ultrasonic motor using the alternative work of the multi-driving end of a single stator was fabricated and investigated experimentally. The traveling speed without load of the slider is 88 mm/s, and the maximum load is 0.32 N.

关键词： ultrasonic motor     intermittent contact     alternative work    

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Investigation on a cylindrical ultrasonic micromotor

ZHU Hua, CHEN Chao, ZHAO Chunsheng

《机械工程前沿（英文）》 2007年 第2卷 第4期   页码 394-398 doi: 10.1007/s11465-007-0068-9

摘要： The relationship between the arrangement of ceramics and the force coefficient shows that the maximum excitation efficiency will be obtained when the ceramics are placed at the trough of the first bending mode of the stator. Therefore, a cylindrical ultrasonic micromotor with a novel stator is proposed. The prototype motor is 5 mm in diameter, 30 mm in length and 4.2 g in weight. The micromotor operates with the first bending mode at 53 kHz. Its maximum speed is 350 r/min when the drive voltage is 200 V and the stall torque reaches 2.5 mN · m. As this motor is suitable for miniaturization because of its simple structure, another cylindrical ultrasonic micromotor is developed. Piezoelectric ceramic tube is used as its stator. This micromtor is 2 mm in diameter, 7 mm in length and 0.258 g in weight. Its speed reaches 813 r/min when the drive voltage is 60 V at 75 kHz. The operation mechanism, structure and design method of these two motors are introduced.

关键词： coefficient     bending     kHz     suitable     weight    

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

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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Performance investigation on ultrasonic levitation axial bearing for flywheel storage system

Taijiang PENG, Zhigang YANG, Junwu KAN, Fengjun TIAN, Xiaohong CHE,

《机械工程前沿（英文）》 2009年 第4卷 第4期   页码 415-419 doi: 10.1007/s11465-009-0051-8

摘要： The bearing is an important basic mechanical part for supporting a shaft. A flywheel storage system needs a type of noncontact support bearing to enhance the speed of the axis. A magnetic suspension bearing is one type of noncontact bearing but has electromagnetic interference to other electric equipment. Based on the performance research of ultrasonic levitation technology, a novel noncontact bearing called ultrasonic bearing is presented, which consists of a special piezoelectric vibrator supporting the load. Experiments are carried out to study the relationships among the amplitude of the vibrator and levitation clearance, the highest speed of the axis, and the frictional moment of the axis. Results show that the levitation clearance becomes smaller gradually with increasing load; the rotation speed is up to 8946 r/min, and the friction moment is only 2.095×10 N·m when the levitation clearance is 8.53 μm. The ultrasonic bearing is highlighted because of its simple structure, strong levitation ability, and low friction moment.

关键词： ultrasonic bearing     flywheel storage system     piezoelectric ceramic     piezoelectric vibrator    

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标题 作者 时间 类型 操作

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

期刊论文

Design of ultrasonic elliptical vibration cutting system for tungsten heavy alloy

期刊论文

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

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

density measurement for plastic injection molding via ultrasonic technology

期刊论文

Linear ultrasonic motor using quadrate plate transducer

Jiamei JIN, Chunsheng ZHAO

期刊论文

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

期刊论文

Improving the performances of ultrasonic motors using intermittent contact scheme

Jiamei JIN, Jianhui ZHANG, Fu QIAN, Zhenfeng PAN,

期刊论文

Investigation on a cylindrical ultrasonic micromotor

ZHU Hua, CHEN Chao, ZHAO Chunsheng

期刊论文

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

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

期刊论文

Performance investigation on ultrasonic levitation axial bearing for flywheel storage system

Taijiang PENG, Zhigang YANG, Junwu KAN, Fengjun TIAN, Xiaohong CHE,

期刊论文