Abstract Rotary ultrasonic machining (RUM) is a hybrid machining process that combines the material removal mechanisms of grinding and ultrasonic machining. RUM has been applied to hole-making for a wide range of materials. It is known that ultrasonic vibration amplitude has significant effects on cutting force, torque, and surface finish in RUM. One experimental observation that has been reported in the literature multiple times states that different tools show different vibration amplitudes on the same ultrasonic power level. However, no analyses can be found in the literature to explain this observation. The existence of this knowledge gap makes it difficult to explain some experimentally obtained trends or to conduct more realistic physics-based modeling work. The objectives of this research are to understand the effects of tool natural frequency on ultrasonic vibration amplitude in RUM, to provide an explanation to the observation and verification of measurement methods, and also to guide tool design and selection in RUM. Ultrasonic vibration amplitudes of tools are measured by three methods and compared. It is found that tool natural frequency significantly affects ultrasonic vibration amplitude. The tool with its natural frequency closest to that of the ultrasonic power supply (20 kHz) generates the highest ultrasonic vibration amplitude on every ultrasonic power level tested.

中文翻译：

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旋转超声加工：刀具固有频率对超声振动幅值的影响

摘要 旋转超声加工 (RUM) 是一种混合加工工艺，它结合了磨削和超声加工的材料去除机制。RUM 已应用于各种材料的孔加工。众所周知，超声振动幅度对 RUM 中的切削力、扭矩和表面光洁度有显着影响。文献中多次报道的一项实验观察表明，不同的工具在相同的超声功率水平上表现出不同的振动幅度。然而，在文献中找不到任何分析来解释这一观察结果。这种知识差距的存在使得难以解释一些实验获得的趋势或进行更现实的基于物理的建模工作。本研究的目的是了解 RUM 中刀具固有频率对超声振动幅值的影响，为测量方法的观察和验证提供解释，并指导 RUM 中刀具的设计和选择。用三种方法测量工具的超声振动幅值并进行比较。发现刀具固有频率显着影响超声振动幅值。固有频率最接近超声波电源 (20 kHz) 的工具在测试的每个超声波功率水平上产生最高的超声波振动幅度。用三种方法测量工具的超声振动幅值并进行比较。发现刀具固有频率显着影响超声振动幅值。固有频率最接近超声波电源 (20 kHz) 的工具在测试的每个超声波功率水平上产生最高的超声波振动幅度。用三种方法测量工具的超声振动幅值并进行比较。发现刀具固有频率显着影响超声振动幅值。固有频率最接近超声波电源 (20 kHz) 的工具在测试的每个超声波功率水平上产生最高的超声波振动幅度。