Proceedings of the
9th International Conference of Asian Society for Precision Engineering and Nanotechnology (ASPEN2022)
15 – 18 November 2022, Singapore

Development of Ultrasonic Transducer with Flexure Hinge for Ultrasonic Spindle Milling

Rendi Kurniawan1, Rendi Kurniawan1, Minki Choo1, Shou Chen1, Yein Kwak1, Saood Ali1, Pilwan Han2 and Tae Jo Ko1,a

1Department of Mechanical Engineering, Yeungnam University, 280 Daehak-Ro, Gyeongsan-si, Gyeongbuk-do, South Korea

2Korea Electrotechnology Research Institute (KERI), 10 beon-gil Bulmosan-ro, Changwon-si, Gyeongsangnam-do, South Korea


This article presents the development of ultrasonic transducer with flexure hinge design for ultrasonic spindle milling (USM) system. The ultrasonic transducer has been designed based on the first mode of longitudinal vibration mode. The ultrasonic transducer has been designed to work at ultrasonic frequency about 30 kHz without considered the tool. However, it was found that the working frequency is between 25 and 27 kHz according to impedance measurement when the tool was installed. The flexure hinge (symmetrical circular shape) on the flange has been utilized to increase the vibration amplitude although the stiffness is downgraded. According to the transient structural analysis, it is confirmed that the thickness and radius of the flexure hinge influenced the displacement output of the Ultrasonic transducer. The simulation results confirm that the displacement output can be produced up to 6.5 µm under given dynamic force 5,120 N with flexure hinge radius of 2.5 mm and thickness of 2.4 mm. The experimental measurement of amplitude has been also carried out to validate the simulation which is confirmed that the amplitude can be produced about more than 20 µm. Next, the performance of ultrasonic spindle is tested by side-milling. The experimental results showed that the performance of ultrasonic spindle milling can improve the machinability in the side-milling of Al 6061 material.

Keywords: Ultrasonic transducer, Simulation transient, Modal analysis, Milling, Cutting force

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