Development of Langevin Piezoelectric Transducer-based Two Dimensional Ultrasonic Vibration Assisted Machining (2D UVAM) on 5-axis Micro-milling Machine

Abstract

The purpose of this study is to design and develop a Two-Dimensional Ultrasonic Vibration Assisted Micro-milling (2D UVAMM) system. Two-dimensional ultrasonic vibrations produced by 2D UVAMM are used to vibrate the workpiece in the micro-milling process. The system is developed using the principle of two Langevin piezoelectric transducers which have the ability to produce ultrasonic vibrations with small vibration amplitude. Process of 2D UVAMM design optimization was done by modal simulation using Finite Element Analysis method. Both Langevin piezoelectric transducers are designed to have symmetrical and asymmetrical vibration modes with the same natural frequency, so that elliptical pattern vibrations can be generated on the workpiece. The 2D UVAMM system operates at a natural frequency of 24 kHz and has an estimated total displacement on the normal and tangential axes respectively 0.766 μm and 0.382 μm. Two power sources with frequency of 24 kHz, phase difference of 90 degrees, and peak-peak voltage of 212 volt were supplied by an ultrasonic generator to excite both of the Langevin piezoelectric transducers. To confirm the developed 2D UVAMM system, experiments were conducted to compare the surface roughness of Aluminum 6061-T6 through micro-milling with conventional method and with additional of the 2D UVAMM system.