Rotary ultrasonic machining is regarded as a superior machining method for hard and brittle materials. It utilizes ultrasonic tool vibration to improve the material machinability, resulting in reduced cutting force and improved machining efficiency. The temperature stability and resonance quality of the ultrasonic system are critical for the reliable generation of ultrasonic vibration. This study presents a temperature-stable and complete-resonance separated rotary giant magnetostrictive ultrasonic (SRGU) system with novelly designed mechanical structures to improve energy transmission and heat dissipation. A theoretical analysis was performed to demonstrate the design principle of the SRGU system. By abolishing the contactless power system of fixed and rotary parts used in the conventional rotary ultrasonic system, and by using a unique incomplete shell, design methods of the mechanical structure, magnetic circuit, and excitation coil of the SRGU system were proposed. A prototype of the SRGU system was then fabricated and tested to verify the feasibility and efficacy of the proposed design methods. The experimental results demonstrated that the SRGU worked well with much-improved ultrasonic vibration stability and better complete resonance as compared to the conventional ultrasonic system. It was found to work with an ultrasonic amplitude of 10 μm for a continual 9 h with a temperature increase of only 3 °C.

旋转式超声波加工被认为是加工硬脆材料的一种优越的加工方法。它利用超声波刀具振动来改善材料的可加工性，从而降低切削力并提高加工效率。超声系统的温度稳定性和共振质量对于超声振动的可靠产生至关重要。本研究提出了一种温度稳定且完全共振分离的旋转巨磁致伸缩超声 (SRGU) 系统，该系统具有新颖设计的机械结构，以改善能量传输和散热。进行了理论分析以证明 SRGU 系统的设计原理。通过取消传统旋转超声系统中使用的固定和旋转部件的非接触式供电系统，并利用独特的不完全外壳，提出了SRGU系统的机械结构、磁路和励磁线圈的设计方法。然后制造并测试了 SRGU 系统的原型，以验证所提出的设计方法的可行性和有效性。实验结果表明，与传统超声系统相比，SRGU 工作良好，超声振动稳定性大大提高，完全共振更好。发现它可以在 10 μm 的超声振幅下连续工作 9 小时，温度仅升高 3 °C。然后制造并测试了 SRGU 系统的原型，以验证所提出的设计方法的可行性和有效性。实验结果表明，与传统超声系统相比，SRGU 工作良好，超声振动稳定性大大提高，完全共振更好。发现它可以在 10 μm 的超声振幅下连续工作 9 小时，温度仅升高 3 °C。然后制造并测试了 SRGU 系统的原型，以验证所提出的设计方法的可行性和有效性。实验结果表明，与传统超声系统相比，SRGU 工作良好，超声振动稳定性大大提高，完全共振更好。发现它可以在 10 μm 的超声振幅下连续工作 9 小时，温度仅升高 3 °C。