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<p>Ultrasonic vibration elliptical machining(UVEM) exhibits significant advantages over common methods for difficult-to-machine materials. However, there are a few studies on the double-bending vibration ultrasonic elliptical machining. Therefore, a double-bending vibration ultrasonic transducer (DBVUT) was proposed, which can achieve 2DOF elliptical vibration in the <i>XOY</i> plane. The principle of excitation was analyzed, modal tuning was carried out, and the influence of the piezoceramics position on performanc of the DBVUT was discussed. A prototype was fabricated and an experimental testing platform was set up. The results indicate the impedance decreased by 65.9% and the output amplitude increased by 40% when the excitation position was located at the antinode. The energy conversion efficiency for the optimized DBVUT was increased from 0.44&#xa0;μm/W to 25&#xa0;μm/W at an amplitude of 3&#xa0;μm, verifying the significant influence of the position of the bending piezoceramics on the vibration output. In addition, the optimized DBVUT can generate stable elliptical trajectories and, the maximum temperature is 36.8℃ under long-term excitation of 15&#xa0;μm. In Al2O3 grinding, UVEM decreased cutting forces by 40.4% and surface roughness (Ra) by 26.7% compared to common grinding (CG). This study provides theoretical support and experimental validation for the optimization of DBVUT performance, providing critical insights for enhancing UVEM capabilities.</p>

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Double-bending ultrasonic transducers for rotary ultrasonic elliptical machining: Design, optimization and experimental evaluation

  • 期刊论文

  • 发表日期：

    2026年3月19日

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  • Jun Hong,
  • Jiping Wu,
  • Jianzhong Ju,
  • Yang Lyu,
  • Hongquan Li,
  • Zhili Long,
  • Zhi Tian

摘要

Ultrasonic vibration elliptical machining(UVEM) exhibits significant advantages over common methods for difficult-to-machine materials. However, there are a few studies on the double-bending vibration ultrasonic elliptical machining. Therefore, a double-bending vibration ultrasonic transducer (DBVUT) was proposed, which can achieve 2DOF elliptical vibration in the XOY plane. The principle of excitation was analyzed, modal tuning was carried out, and the influence of the piezoceramics position on performanc of the DBVUT was discussed. A prototype was fabricated and an experimental testing platform was set up. The results indicate the impedance decreased by 65.9% and the output amplitude increased by 40% when the excitation position was located at the antinode. The energy conversion efficiency for the optimized DBVUT was increased from 0.44 μm/W to 25 μm/W at an amplitude of 3 μm, verifying the significant influence of the position of the bending piezoceramics on the vibration output. In addition, the optimized DBVUT can generate stable elliptical trajectories and, the maximum temperature is 36.8℃ under long-term excitation of 15 μm. In Al2O3 grinding, UVEM decreased cutting forces by 40.4% and surface roughness (Ra) by 26.7% compared to common grinding (CG). This study provides theoretical support and experimental validation for the optimization of DBVUT performance, providing critical insights for enhancing UVEM capabilities.