Longitudinal-torsional complex-mode ultrasonic actuator for vibration-assisted drilling of CFRP

IF 2.7 4区工程技术 Q2 ENGINEERING, MANUFACTURING

Machining Science and Technology Pub Date : 2022-09-03 DOI:10.1080/10910344.2023.2181089

Chen Zhang, Xiaoxue Wang, V. Silberschmidt

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引用次数: 0

Abstract

Abstract Carbon-fiber-reinforced plastic (CFRP) composites are intensively used in aircraft and aerospace industry thanks to their superior properties. Comparing to the conventional drilling (CD), vibration-assisted drilling (VAD) is a novel machining technique suitable for drilling CFRP. Still, multi-mode excitations with elliptical locus and low vibration performance limit the applications of current VAD schemes for CFRP. To overcome these limitations and improve the overall performance, an innovative longitudinal-torsional complex-mode ultrasonic vibration-assisted actuator with single excitation and an elliptical locus is presented employing a piezoelectric transducer and a stepped horn with spiral grooves. The proposed actuator is specially designed to deliver elliptical vibration and assure high vibration performance of a tool tip. Analysis of the actuation mechanism for the longitudinal-torsional composite vibration mode is discussed, and its simplified model is developed. A detailed design process of this actuator is given. Its vibration characteristics are verified with both finite-element simulation and experimental modal analysis using a swept sine test. It is demonstrated the developed prototype achieved longitudinal-torsional elliptical vibration. To validate the machining performance of the actuator, two groups of drilling experiments were performed. These indicate that the proposed actuator is capable of drilling CFRP with improved machining performance.

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CFRP振动辅助钻孔纵扭复合模超声执行器

摘要碳纤维增强塑料（CFRP）复合材料以其优异的性能在航空航天工业中得到了广泛的应用。与传统钻孔（CD）相比，振动辅助钻孔（VAD）是一种适用于CFRP钻孔的新型加工技术。然而，椭圆轨迹的多模式激励和低振动性能限制了当前碳纤维增强塑料VAD方案的应用。为了克服这些限制并提高整体性能，提出了一种创新的单激励椭圆轨迹纵扭复模态超声振动辅助执行器，该执行器采用压电换能器和带螺旋槽的阶梯喇叭。所提出的致动器是专门设计的，用于传递椭圆振动并确保工具尖端的高振动性能。对纵扭复合振动模式的驱动机构进行了分析，建立了其简化模型。给出了该执行机构的详细设计过程。通过有限元模拟和正弦扫频试验模态分析验证了其振动特性。实验证明，所研制的样机实现了椭圆纵扭振动。为了验证致动器的加工性能，进行了两组钻孔实验。这表明所提出的致动器能够在提高加工性能的情况下钻出CFRP。

本文章由计算机程序翻译，如有差异，请以英文原文为准。

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来源期刊

Machining Science and Technology 工程技术-材料科学：综合

CiteScore

5.70

自引率

3.70%

发文量

审稿时长

6 months

期刊介绍： Machining Science and Technology publishes original scientific and technical papers and review articles on topics related to traditional and nontraditional machining processes performed on all materials—metals and advanced alloys, polymers, ceramics, composites, and biomaterials. Topics covered include: -machining performance of all materials, including lightweight materials- coated and special cutting tools: design and machining performance evaluation- predictive models for machining performance and optimization, including machining dynamics- measurement and analysis of machined surfaces- sustainable machining: dry, near-dry, or Minimum Quantity Lubrication (MQL) and cryogenic machining processes precision and micro/nano machining- design and implementation of in-process sensors for monitoring and control of machining performance- surface integrity in machining processes, including detection and characterization of machining damage- new and advanced abrasive machining processes: design and performance analysis- cutting fluids and special coolants/lubricants- nontraditional and hybrid machining processes, including EDM, ECM, laser and plasma-assisted machining, waterjet and abrasive waterjet machining