Compound ultrasonic vibration systems with a complex disk tool: Local resonance characteristics, FEM-based modal analysis, and design method

• Published in: Advances in mechanical engineering Vol. 17; no. 1
• Main Authors: Zhang, Cunying, Bie, Wenbo, Liu, Yu, Chen, Fan
• Format: Journal Article
• Language: English
• Published: London, England SAGE Publications 01.01.2025; Sage Publications Ltd; SAGE Publishing
• Subjects: CAE; Computer aided engineering; Cutting tools; Design techniques; Machining; Modal analysis; Position measurement; Resonance; Resonant frequencies; Simulation; Simulation models; Software; Surface properties; Ultrasonic vibration; Vibration analysis; Vibration measurement; non-resonant system; local resonance; Complex disk; compound vibration system; ultrasonic vibration
• ISSN: 1687-8132; 1687-8140
• DOI: 10.1177/16878132251314323

Good machining performance and high surface quality can be achieved in engineering compound materials when subjected to ultrasonic vibration machining systems. This study established an ultrasonic vibration system with a complex disk tool. The finite element simulation model of the complex disk tool was created using ANSYS software. Modal analysis was utilized to obtain the disk’s resonance frequency and other parameters. Based on the local resonance characteristics of the system and the simulation results, the horn, transducers, and other components were designed. The node position of the compound ultrasound system can be accurately determined, leading to the acquisition of a cutting disc with a disc-shaped cutting edge that exhibits equal center distance and amplitude longitudinal vibration in the ultrasonic vibration system. This vibration system conforms to the local resonance theory of slender rods. A theoretical method for calculating the nodes of the ultrasonic vibration system with a discoid non-resonant frequency was developed. A slight deviation between the measured resonance frequency of the system and the theoretical results was observed. Thus, a reliable design method for ultrasonic vibration cutting systems with complex disk tools has been provided.