The performance and design of ultrasonic vibration system for flexural mode

Design and Experimental Study of Longitudinal-Torsional Composite Ultrasonic Internal Grinding Horn

Longitudinal-torsional composite ultrasonic vibration has been widely used in grinding. This paper aims to solve the problem that the resonance frequency deviates greatly from the theoretical design frequency and the vibration mode is poor when the horn is matched with a larger tool head. This paper presents how the longitudinal-torsional composite ultrasonic conical transition horn was designed and optimized by the transfer matrix theory and finite element simulation. For this purpose, the spiral groove parameters were optimized and selected by finite element simulation. Then, the modal analysis and transient dynamic analysis of the horn with grinding wheel were carried out to verify the correctness of the theoretical calculation. The impedance analysis and amplitude test of the horn with grinding wheel were carried out. The test results were in very good agreement with the theoretical and simulation results. Finally, the grinding experiment was carried out. The surface roughness of the workpiece in longitudinal-torsional ultrasonic vibration grinding was obviously reduced compared to that of ordinary grinding. All these obtained results demonstrate that the designed longitudinal-torsional composite ultrasonic horn has very good operational performance for practical applications.

Design and development of two-dimensional ultrasonic horn with B-spline curve based on orthogonal method

The ultrasonic horn is the core component in ultrasonic-assisted micro-injection molding (UμIM). UμIM is a complex process with high temperature, high pressure, and high speed, and it is required that the ultrasonic horn should have a reliable performance to ensure the stability of its work. Therefore, the design of the ultrasonic horn is of great significance. Considering the demands for ultrasonic vibration energy in different filling directions in molding for the polymer parts with complex structures, the cubic B-spline curve transition section optimized based on orthogonal analysis is introduced into designing the stepped ultrasonic horn, and the two-dimensional ultrasonic vibration system (2D-UVS) with different resonant frequencies is constructed. The results indicate that the middle two control points of the cubic B-spline curve significantly affect the output performance of the 2D-UVS by means of constructing different cross-sectional profiles of the transition section, and showed different effects at different frequencies. In the paper, an optimal B-spline curve transition section is designed and constructed by optimizing the positions of the control points to receive a more balanced performance in terms of the desired frequency, amplification, and strength. The measurement results show that a two-dimensional ultrasonic vibration with trajectory stability of more than 95% is created from the front end of the horn, and the two-dimensional ultrasonic vibration trajectory can be controlled by different energizing voltage amplitudes and phase differences.

Study on the bending vibration of bimorph rectangular transducer based on type 2-2 piezoelectric composites

In order to improve the acoustic radiation capability of piezoelectric ultrasonic transducer in gas, a bimorph rectangular transducer based on type 2-2 piezoelectric composites is proposed in this paper, which is composed of two piezoelectric composite rectangular slices with thickness polarization. First, the bending vibration of the rectangular transducer is divided into two bending vibrations of the thin rods in the x and y directions using the equivalent elastic method. When the mechanical coupling coefficient is introduced and combined with the anisotropic piezoelectric equations, the resonance frequency equations of the thickness-polarized transducer are derived with simply supported boundary conditions. Then the bending vibration of the transducer is numerically simulated. The results show that the resonance frequency obtained by the analytical method is in good agreement with the numerical simulation results. Finally, the influence of geometrical size and two-phase volume ratio on the bending vibration performance of the transducer is analyzed. Compared with the piezoelectric bimorph transducer, the piezoelectric composite bimorph transducer has a larger bending vibration displacement amplitude, a larger transmitting voltage response, a lower resonant frequency and better acoustic radiation capability.

Study on tangentially polarized composite cylindrical piezoelectric transducer with high electro-mechanical coupling coefficient

In this work, we proposed an effective way to fabricate a tangentially polarized composite cylindrical transducer with high electro-mechanical coupling coefficient (EMCC) by radially connecting an inner tangential polarized piezoelectric tube with an outer metal ring. The resonance frequency and EMCC of the proposed transducer are calculated according to frequency equations, which are obtained from the equivalent circuit of the transducer, and the results indicate that EMCC of the tangentially polarized cylindrical transducer is much higher than that of the cylindrical transducer polarized in radial direction. Furthermore, the Finite Element Method (FEM) model of the transducer is established and used for numerical simulation of the vibration models and the optimum configuration parameters. On the basis of those theoretical results, serials of prototype transducers are manufactured with an inner tangential polarized piezoelectric tube connecting with different outer metal cylindrical shells. The admittance characteristics of the fabricated transducers measured by Impedance Analyzer clearly demonstrate that the resonance frequencies of the transducers are in good agreement with those of simulation results, and the effective EMCC of transducers varies with the material of metal cylindrical shell, in which aluminum metal shell possesses the highest EMCC.

An efficient approach to optimize the vibration mode of bar-type ultrasonic motors

The electromechanical coupled dynamic model of the stator of the bar-type ultrasonic motor is derived based on the finite element method. The dynamical behavior of the stator is analyzed via this model and the theoretical result agrees with the experimental result of the stator of the prototype motor very well. Both the structural design principles and the approaches to meet the requirements for the mode of the stator are discussed. Based on the pattern search algorithm, an optimal model to meet the design requirements is established. The numerical simulation results show that this optimal model is effective for the structural design of the stator.

Modeling of flexible waveguides for ultrasonic vibrations transmission: longitudinal and flexural vibrations of non-deformed waveguide

The article presents the mathematical model allowing to investigate longitudinal and flexural vibrations of stepped flexible waveguides with transitional section without regard to various vibration modes interaction. The model uses original numerical-analytic calculations based on analytical solutions of the equation of waveguide steps vibrations and their continuous matching with numerical solution of the equation of transitional section vibrations. The proposed model can be considered as an initial approximation to the solution of the problem of flexible waveguides design, which makes it possible to determine and validate effective methods of its addressing. Resonant curves of longitudinal and flexural vibrations of two-step waveguide are traced for the given vibration frequency. Step lengths values providing simultaneous resonance of longitudinal and flexural vibrations for the given frequency are determined. Validity of the proposed model is proved by the results of finite elements method (FEM) modeling using ANSYS software. Application of Timoshenko's model instead of Euler-Bernoulli's model for description of flexural vibrations enabled reduction of relative deviation of resonant frequencies calculated using ANSYS from the value specified during resonant curves tracing down to negligible value (0.17%).

Study on a new type of radial composite piezoelectric ultrasonic transducers in radial vibration

In this paper, a new type of radial composite ultrasonic transducers in radial vibration is presented and studied. The radial composite ultrasonic transducer consists of a solid piezoelectric ceramic thin disk and a hollow metal thin, circular ring in radial vibration; and they are connected together in the radial direction. The radial vibrations of a piezoelectric ceramic thin disk and a hollow, metal, thin, circular ring are analyzed, respectively. Their radial electromechanical equivalent circuits are obtained. Based on the electromechanical equivalent circuits and using the boundary conditions between the piezoelectric ceramic thin disk and the hollow, metal, thin ring, the electromechanical equivalent circuit of the radial composite ultrasonic transducer is derived and the resonance frequency equation is obtained. The theoretical results from the resonance frequency equation are in good agreement with the measured radial resonance frequencies, and they also are in a good agreement with the results from the numerical method.

Computer generated optical holographic fringe patterns for the analysis of vibrating structures

Optical holographic interference fringe patterns on rods and bars vibrating in ultrasonic resonance (standing waves) are predicted by computer simulations. The simulations are based on a combination of finite element calculations with calculations based on the theory of holographic interference fringe generation. The hypothetical fringe patterns are then compared to holographic fringe images obtained by the experiment (time average holograms). The holographic arrangement and the mechanical part of the ultrasonic system (transducer, horn and specimen) were fixed on a commercial rigid optical table supported on air bags to isolate it from ground vibrations. Thus it is shown that the scope of the study can be reached with a minimum of experimental effort, i.e., with basic laser optical equipment. It is shown that provided the system operates in the desired mode, good agreement between the theoretical and the real image is given. Finally examples of the possible influence of defects or of parasitic modes of vibration on the appearance of the fringe patterns are given.

The complex-mode vibration of ultrasonic vibration systems

The longitudinal-flexural and torsional-flexural vibrations are studied for the ultrasonic solid horn and the ultrasonic vibration system comprised of a sandwich transducer and a solid horn. The discussed solid horn is of arbitrary non-uniform cross-section. The analysis on flexural-mode vibration is based on Timoshenko theory. The theoretical results are verified by experiment.