Development of an innovative device for ultrasonic elliptical vibration cutting

• 1st resonant mode of longitudinal vibration and 3rd resonant mode of bending vibration were adopted in the ultrasonic elliptical vibration cutting device.
• The output power and vibration amplitude of the device are improved.
• Single node fixed support was adopted in this work.

An innovative ultrasonic elliptical vibration cutting (UEVC) device with 1st resonant mode of longitudinal vibration and 3rd resonant mode of bending vibration was proposed in this paper, which can deliver higher output power compared to previous UEVC devices. Using finite element method (FEM), resonance frequencies of the longitudinal and bending vibrations were tuned to be as close as possible in order to excite these two vibrations using two-phase driving voltages at a single frequency, while wave nodes of the longitudinal and bending vibrations were also adjusted to be as coincident as possible for mounting the device at a single fixed point. Based on the simulation analysis results a prototype device was fabricated, then its vibration characteristics were evaluated by an impedance analyzer and a laser displacement sensor. With two-phase sinusoidal driving voltages both of 480 Vp–p at an ultrasonic frequency of 20.1 kHz, the developed prototype device achieved an elliptical vibration with a longitudinal amplitude of 8.9 μm and a bending amplitude of 11.3 μm. The performance of the developed UEVC device is assessed by the cutting tests of hardened steel using single crystal diamond tools. Experimental results indicate that compared to ordinary cutting process, the tool wear is reduced significantly by using the proposed device.