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Design of Piezoelectric Ultrasonic Composite Vibration System for Precision Grinding
Weiqing Huang1, Kaijie Huang1, Qunyou Zhong1
1School of Mechanical and Electrical Engineering, Guangzhou University, Guangzhou 510006, China.
Micromachines
|April 26, 2025
Summary
Ultrasonic machining with longitudinal-torsional vibration significantly improves sapphire surface quality. This advanced method reduces surface roughness and enhances flatness compared to traditional techniques.
Area of Science:
- Materials Science
- Mechanical Engineering
- Manufacturing Technology
Background:
- Sapphire's hardness and brittleness pose challenges for traditional machining, leading to surface defects like scratches and microcracks.
- Ultrasonic machining offers an advanced solution for processing hard-brittle materials, aiming to minimize damage and enhance surface finish.
Purpose of the Study:
- To design and validate an integrated ultrasonic longitudinal-torsional vibration system for machining sapphire.
- To investigate the impact of machining parameters on sapphire surface roughness (Ra) and material removal rate (MRR).
- To compare the effectiveness of longitudinal-torsional vibration against pure longitudinal vibration in sapphire grinding.
Main Methods:
- Simulation and experimental testing of a novel ultrasonic longitudinal-torsional vibration system, including horn design and amplitude analysis.
- Conducting comparative grinding experiments on sapphire workpieces using different vibration modes.
- Analyzing surface roughness (Ra) and surface flatness using experimental data.
Main Results:
- The designed ultrasonic system achieved a resonant frequency of 19.857 kHz with specific longitudinal (4.2 µm) and torsional (1.8 µm) amplitudes.
- Ultrasonic longitudinal-torsional grinding reduced sapphire surface roughness from 960.6 nm to 82.6 nm and improved flatness to 84.3 nm.
- Compared to longitudinal vibration, longitudinal-torsional vibration decreased surface roughness by 48% and increased surface flatness by 88.3%.
Conclusions:
- The integrated ultrasonic longitudinal-torsional vibration system is effective for machining hard-brittle materials like sapphire.
- This composite vibration method offers superior surface quality improvements over conventional ultrasonic longitudinal vibration.
- The findings provide practical guidelines for applying composite ultrasonic machining to enhance the processing of sapphire and similar materials.
