Development of an Ultrasonic Torsional Vibration Tool Utilizing the 3rd Order Wave Mode

• Published in: Key engineering materials 2003-01, Vol.238-239, p.349-354
• Main Authors: Iwai, Manabu, Suzuki, Kiyoshi, Uematsu, Tetsutaro, Sharma, Anurag, Mishiro, Shoji, Qun, Hu Bin, Imai, Tomoyasu
• Format: Article
• Language: English
• ISSN: 1013-9826; 1662-9795; 1662-9795
• DOI: 10.4028/www.scientific.net/KEM.238-239.349

Considering the large potential in using the complex mode ultrasonic vibration in material removal processes, a high frequency torsional vibration mode transducer has been recently fabricated, which is capable of imparting a vibration frequency 3 times the resonance frequency of the fabricated tool body. An electroplated diamond abrasive horn is mounted to this device and a plunge grinding test is carried out by installing this tool on the main spindle of a vertical machining center. A frequency in the vicinity of 61 kHz has been used in this experimental grinding operation. The grinding resistance, grinding efficiency, and the characteristics of the ground workpiece surface (S45C) have been examined with reference to the application of the vibration and without the application of vibration to the tool. A remarkable reduction in the grinding resistance is observed when the vibration is applied to the grinding tool. An almost three fold improvement in grinding ratio indicated an encouraging result. Along with this, the surface finish has improved greatly. Burr formation on the edge of the hole made in the workpiece is observed for diamond abrasive SD600 but such continuous burrs can easily be removed by a simple secondary operation. In case of the SD1000 diamond abrasive tool, burr formation can be suppressed by the application of the vibration.