A critical review of piezoelectric ultrasonic transducers for ultrasonic-assisted precision machining

Piezoelectric ultrasonic-assisted precision machining (PUAPM) technology is considered to be an efficient and environmentally friendly machining strategy by virtue of cutting force reduction, ductile cutting promotion, tool wear and machining noise reduction. Piezoelectric ultrasonic transducer (PUT) provides ultrasonic energy for PUAPM system, which is the core component to ensure the normal operation of the system. PUTs for PUAPM devices have emerged endlessly in recent decades and have been successfully applied in many fields, such as MEMS, biomedicine, optoelectronics, aerospace, etc. However, there is no comprehensive classification and analysis of the basic configurations, excitation principles, typical structures, performance analyses and control strategies for PUT. This work gives a critical review of research on PUT in recent years, especially the structural optimization, application expansion and ultrasonic energy stabilization in PUAPM. The influence mechanism of excitation mode, modal type, modal combination, horn structure and ceramic arrangement on the optimization of PUT structure is summarized. The improvement effect and mechanism of PUT vibration dimension, amplitude, frequency and structural characteristics on surface roughness, surface texture and cutting force are discussed. In addition, the causes of PUT amplitude fluctuation, and the influence of sensing and control methods on PUT amplitude regulation and system integration are analyzed. This review will help in understanding the current development and diversified applications of PUT and will promote the application of ultrasonic technology in more fields.