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Dynamic ultrasonic contact detection using acoustic emissions.

S L Turner1, A Rabani2, D A Axinte2

  • 1Machining and Condition Monitoring Group, Faculty of Engineering, University of Nottingham, University Park, Nottingham NG7 2RD, UK; Zeeko Ltd., 4 Vulcan Court, Coalville, Leicestershire LE67 3FW, UK.

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Summary
This summary is machine-generated.

This study introduces a non-contact method for precise ultrasonic machining. It uses acoustic emissions to detect near-contact distances, enabling accurate standoff control for critical applications.

Keywords:
Acoustic emissionDynamic standoff detectionNon-contact ultrasonic machining

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Area of Science:

  • Manufacturing Engineering
  • Materials Science
  • Acoustics

Background:

  • Precise standoff control (<20 μm) is critical for non-contact ultrasonic material removal.
  • Current methods rely on physical contact or indirect measurements, which are insufficient for sub-20 μm precision.

Purpose of the Study:

  • To develop a non-contact method for determining the precise standoff distance in ultrasonic machining.
  • To establish a reliable mechanism for detecting near-contact conditions without physical interaction.

Main Methods:

  • Utilizing acoustic emissions (AE) detected through the workpiece to monitor ultrasonic tool proximity.
  • Analyzing the amplitude changes of the fundamental frequency and its harmonics (2nd and 3rd) as indicators of distance.

Main Results:

  • A significant increase in the fundamental frequency amplitude occurs at the point of contact.
  • The 2nd and 3rd harmonic signal intensities increase more markedly at contact.
  • Harmonic intensity increases are observable within 10 μm prior to actual contact.

Conclusions:

  • A novel non-contact method for standoff detection using AE harmonics is demonstrated.
  • This technique allows for precise standoff setting (<10 μm) without initial surface contact.
  • The findings offer improved control for high-precision ultrasonic machining processes.