{"title":"Implementation of new stepped horn in rotary ultrasonic machining of NOMEX honeycomb composites","authors":"Shahzad Ahmad","doi":"10.1007/s12206-024-0834-1","DOIUrl":null,"url":null,"abstract":"<p>Performance of rotary ultrasonic machining (RUM) system greatly influences by appropriate design of ultrasonic horn. Ultrasonic stepped horn gives high amplitude of vibration and better cutting efficiency but design and integration of horn with RUM system is highly intricate. Therefore, systematic study on design and implementation of ultrasonic stepped horn was needed in order to achieve better efficiency of RUM process. This paper focuses on design aspects of ultrasonic stepped horn by theoretical, FE simulations and modeling techniques. The designed horn was integrated with RUM system, performance was measured in terms of ultrasonic resonant frequency through FE simulations and modeling on ANSYS workbench. Finally, fabricated ultrasonic stepped horn was validated by performing experiments on rotary ultrasonic machine tool for Nomex honeycomb composites (NHCs). FE simulations and experimental results prove that the designed ultrasonic stepped horn achieves reasonable vibration amplitude at desired resonant frequency to perform RUM process on NHCs materials.</p>","PeriodicalId":16235,"journal":{"name":"Journal of Mechanical Science and Technology","volume":null,"pages":null},"PeriodicalIF":1.5000,"publicationDate":"2024-09-03","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":"0","resultStr":null,"platform":"Semanticscholar","paperid":null,"PeriodicalName":"Journal of Mechanical Science and Technology","FirstCategoryId":"5","ListUrlMain":"https://doi.org/10.1007/s12206-024-0834-1","RegionNum":4,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":null,"EPubDate":"","PubModel":"","JCR":"Q3","JCRName":"ENGINEERING, MECHANICAL","Score":null,"Total":0}
引用次数: 0
Abstract
Performance of rotary ultrasonic machining (RUM) system greatly influences by appropriate design of ultrasonic horn. Ultrasonic stepped horn gives high amplitude of vibration and better cutting efficiency but design and integration of horn with RUM system is highly intricate. Therefore, systematic study on design and implementation of ultrasonic stepped horn was needed in order to achieve better efficiency of RUM process. This paper focuses on design aspects of ultrasonic stepped horn by theoretical, FE simulations and modeling techniques. The designed horn was integrated with RUM system, performance was measured in terms of ultrasonic resonant frequency through FE simulations and modeling on ANSYS workbench. Finally, fabricated ultrasonic stepped horn was validated by performing experiments on rotary ultrasonic machine tool for Nomex honeycomb composites (NHCs). FE simulations and experimental results prove that the designed ultrasonic stepped horn achieves reasonable vibration amplitude at desired resonant frequency to perform RUM process on NHCs materials.
旋转式超声波加工（RUM）系统的性能在很大程度上受到超声波喇叭设计的影响。阶梯式超声波号角具有高振幅和更好的切割效率，但号角的设计和与 RUM 系统的集成非常复杂。因此，需要对超声波阶梯喇叭的设计和实施进行系统研究，以提高 RUM 加工的效率。本文通过理论、有限元模拟和建模技术，重点研究了超声波阶梯喇叭的设计问题。设计的喇叭与 RUM 系统集成，并通过 ANSYS 工作台上的有限元模拟和建模测量了超声共振频率的性能。最后，通过在旋转式超声波机床上对 Nomex 蜂窝复合材料（NHC）进行实验，对制作的超声波阶梯喇叭进行了验证。有限元模拟和实验结果证明，所设计的阶梯式超声波喇叭在所需的共振频率下实现了合理的振幅，可以对 NHC 材料进行 RUM 加工。
期刊介绍：
The aim of the Journal of Mechanical Science and Technology is to provide an international forum for the publication and dissemination of original work that contributes to the understanding of the main and related disciplines of mechanical engineering, either empirical or theoretical. The Journal covers the whole spectrum of mechanical engineering, which includes, but is not limited to, Materials and Design Engineering, Production Engineering and Fusion Technology, Dynamics, Vibration and Control, Thermal Engineering and Fluids Engineering.
Manuscripts may fall into several categories including full articles, solicited reviews or commentary, and unsolicited reviews or commentary related to the core of mechanical engineering.
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