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Investigation of the longitudinal-flexural resonating spindle in ultrasound-assisted grinding of SiCp/Al composites

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Abstract

Rotary ultrasonic machining is a cost-effective and precise machining method for hard and brittle materials. Aiming at processing SiCp/Al composites, a rotary ultrasonic grinding spindle is proposed in the present study. Expressions were established to calculate the displacement, rotation angle, bending moment, and shear force of the vibrating elements based on the Mindlin moderately thick plate theory. Combining continuous and boundary conditions of vibrating elements with the proposed expressions, the vibration model and frequency equation of a longitudinal-flexural resonating transformer with a large load were established. Then two transformers were designed according to the frequency equation. The resonant characteristics of the transformers were studied using finite element analysis, impedance analysis, and ultrasonic resonance experiments. The obtained results show that the maximum deviation between the resonant frequency and the design frequency of the transformers was 4.95%. Moreover, the maximum deviation of the positions of the pitch circles was 6.51%. It is concluded that the proposed designs have high accuracy. Finally, the orthogonal single-factor experiments of SiCp/Al composites were performed with and without ultrasound. The obtained results show that introducing ultrasonic vibrations significantly reduces the grinding force and the surface roughness while improving the surface quality of the SiCp/Al workpiece. The present study is expected to provide experimental fundamentals to further improve the structure of the grinding spindle, optimize process variables of ultrasound-assisted grinding, and improve the processing efficiency.

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Data and materials are available from the corresponding author upon reasonable request.

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Funding

This work was supported by the Transformation of Scientific and Technological Achievements Programs of Higher Education Institutions in Shanxi (Grant No. 2020CG033) and the National Natural Science Foundation of China (Grant No. 51975540 and Grant No. 52005455).

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Authors and Affiliations

  1. Shanxi Key Laboratory of Advanced Manufacturing Technology, North University of China, Taiyuan, 030051, China

    Xiao Wu, Huibin Qin, Xijing Zhu, Yi Feng, Ruifeng Zhou & Linzheng Ye

  2. School of Mechanical Engineering, North University of China, Taiyuan, 030051, China

    Xiao Wu, Huibin Qin, Xijing Zhu, Yi Feng, Ruifeng Zhou & Linzheng Ye

Authors
  1. Xiao Wu
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  2. Huibin Qin
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  3. Xijing Zhu
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  4. Yi Feng
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  5. Ruifeng Zhou
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  6. Linzheng Ye
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Contributions

WX contributed significantly to the conception of the study and wrote the manuscript. QHB revised the manuscript. ZXJ contributed to the data analysis of the manuscript. FY and ZRF designed and performed the experiments. YLZ helped to perform the analysis with constructive discussions.

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Correspondence to Xijing Zhu.

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Wu, X., Qin, H., Zhu, X. et al. Investigation of the longitudinal-flexural resonating spindle in ultrasound-assisted grinding of SiCp/Al composites. Int J Adv Manuf Technol 121, 3511–3526 (2022). https://doi.org/10.1007/s00170-022-09569-3

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