Finite Element Analysis and Fabrication of an Ultrasonic Milling System

다국어 초록 (Multilingual Abstract)

Ultrasound has been adapted in several industrial and manufacturing applications. In this study, an ultrasonic milling system, which can vibrate a rotating tool, was designed and fabricated. Firstly, a lead zirconate titanate (PZT) was designed using finite element analysis, and the obtained peak impedance value of 47.2 ㎑ agreed well with the fabricated PZT value of 48.0 ㎑. Additionally, an aluminum waveguide with two PZT actuators was analyzed, whose impedance characteristic was predicted to be 43.8 ㎑. Consequently, a milling waveguide was fabricated using the analysis results. The impedance value of the fabricated waveguide was measured to be 42.7 ㎑, which was consistent with the finite element analysis result with an error of 2.6 %. The rotational speed and power output were measured to be 10,001 rpm and 122.6 W. Thus, the developed milling waveguide can be applied to the milling process of high-hardness metals.