Skip to main content
SpringerLink
Log in

Design optimization of cubic Bezier horn for ultrasonic machining

  • Published:
Sādhanā Aims and scope Submit manuscript

Abstract

In ultrasonic machining (USM), higher amplitude is required for higher material removal rate (MRR). The objective of this research is to develop a new horn design for high displacement amplitude for getting maximum MRR within a working condition. The profile of the horn has been optimized and designed. In this analysis, optimization procedure and finite-element method have been used for the design of horn of USM. In this, the variation of stress components along the length of the horn has been studied. In the middle, maximum stress is found due to a change in cross-section but it is within the endurance limit of the horn material. The cubic Bezier horn as compared with traditional horn is up to 19% more amplified. Finally, an optimized cubic Bezier profile for the horn has been designed, which has maximum displacement amplitude for higher MRR and safe working stresses for the horn material.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Log in via an institution

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Figure 1
Figure 2
Figure 3
Figure 4
Figure 5
Figure 6
Figure 7
Figure 8
Figure 9
Figure 10
Figure 11
Figure 12

Similar content being viewed by others

References

  1. Rozenberg L D, Kazantsev V F, Makarov L O and Yakhimovich D F 1964 Ultrasonic cutting. New York: Consultants Bureau

    Google Scholar 

  2. Roy S and Jagadish 2017 Design of a circular hollow ultrasonic horn for USM using finite element analysis. Int. J. Adv. Manuf. Technol. 93: 319–328

    Article  Google Scholar 

  3. Jain V K 2002 Advanced machining processes. New Delhi (India): Allied

    Google Scholar 

  4. Ghosh A and Mallik A K 1985 Manufacturing science. New Delhi (India): EWP Pvt. Ltd.

    Google Scholar 

  5. Pandey C P and Shah H S 2003 Modern machining processes. New Delhi (India): TMH

    Google Scholar 

  6. Mishra P K 1997 Nonconventional machining. New Delhi (India): Narosa Book Distributors Pvt. Ltd.

    Google Scholar 

  7. Choi Y J, Park K H, Hong Y H, Kim K T, Lee S W and Choi H Z 2013 Effect of ultrasonic vibration in grinding; horn design and experiment. Int. J. Precis. Eng. Manuf. 14: 1873–1879

    Article  Google Scholar 

  8. Jung W, Ra J and Park K 2012 Design optimization of ultrasonic horn for micro-pattern replication. Int. J. Precis. Eng. Manuf. 13: 2195–2201

    Article  Google Scholar 

  9. Seah K H W, Wong Y S and Lee L C 1993 Design of tool holders for ultrasonic machining using FEM. J. Mater. Process. Technol. 37: 801–816

    Article  Google Scholar 

  10. Amin S G, Ahmed M H M and Youssef H A 1995 Computer-aided design of acoustic horns for ultrasonic machining using finite-element analysis. J. Mater. Process. Technol. 55: 254–260

    Article  Google Scholar 

  11. Yadava V and Deoghare A 2008 Design of horn for rotary ultrasonic machining using the finite element method. Int. J. Adv. Manuf. Technol. 39: 9–20

    Article  Google Scholar 

  12. Rosca I C, Pop M I and Cretu N 2015 Experimental and numerical study on an ultrasonic horn with shape designed with an optimization algorithm. Appl. Acoust. 95: 60–69

    Article  Google Scholar 

  13. Thoe T B, Aspinwall D K and Wise M L H 1998 Review on ultrasonic machining. Int. J. Mach. Tool. Manuf. 38: 239–255

    Article  Google Scholar 

  14. Wang D A, Chuang W Y, Hsu K and Pham H T 2011 Design of a Bézier-profile horn for high displacement amplification. Ultrasonics 51: 148–156

    Article  Google Scholar 

  15. Jagadish and Ray A 2018 Design and performance analysis of ultrasonic horn with a longitudinally changing rectangular cross section for USM using finite element analysis. J. Braz. Soc. Mech. Sci. Eng. 40: 1–11

    Article  Google Scholar 

  16. Zeid I 1998 CAD/CAM theory and practice. New Delhi (India): Tata McGraw-Hill Edition

    Google Scholar 

  17. Deb K, Pratap A, Agarwal S and Meyarrivan T 2002 A fast and elitist multiobjective genetic algorithm NSGA-II. IEEE Trans. Evol. Comput. 6:182-197

    Article  Google Scholar 

  18. Anand K and Elangovan S 2019 Modelling and multi-objective optimization of ultrasonic inserting parameters through fuzzy logic and genetic algorithm. J. Braz. Soc. Mech. Sci. Eng. 41: 1–20

    Article  Google Scholar 

  19. Goldberg D E 1989 Genetic algorithms in search, optimization and machine learning. MA: Addison Wesley Publishing Company

    MATH  Google Scholar 

  20. Reddy J N 2005 An introduction to finite element method. New Delhi (India): Tata McGraw-Hill Edition

    Google Scholar 

  21. Kwon Y W and Bang H 2000 The finite element method using MATLAB. USA: CRC Press

    MATH  Google Scholar 

  22. Belegundu A D and Chandrupatla R T 2008 Introduction to finite elements in engineering. India: PHI

    MATH  Google Scholar 

  23. He T, Ye X Q and Zhao Y 2015 Optimization design for ultrasonic horn with large amplitude based on genetic algorithm. J. Vibroeng. 17: 1157–1168

    Google Scholar 

  24. Naseri R, Koohkan K, Ebrahimi M, Djavanroodi F and Ahmadian H 2017 Horn design for ultrasonic vibration-aided equal channel angular pressing. Int. J. Adv. Manuf. Technol. 90: 1727–1734

    Article  Google Scholar 

  25. Timoshenko P S, Weaver W and Young D H 1990 Vibration problems in engineering. Singapore: Wiley

    Google Scholar 

  26. Timoshenko S P and Goodier J N 1970 Theory of elasticity. Singapore: International edition

    MATH  Google Scholar 

  27. Kumar V and Singh H 2018 Machining optimization in rotary ultrasonic drilling of BK-7 through response surface methodology using desirability approach. J. Braz. Soc. Mech. Sci. Eng. 40: 1–14

    Article  Google Scholar 

Download references

Author information

Authors and Affiliations

  1. Mechanical Engineering Department, Motilal Nehru National Institute of Technology Allahabad, Prayagraj, 211004, India

    Praveen Kumar Rai, Vinod Yadava & Rabindra Kumar Patel

Authors
  1. Praveen Kumar Rai
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. Vinod Yadava
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. Rabindra Kumar Patel
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding author

Correspondence to Rabindra Kumar Patel.

Rights and permissions

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Rai, P.K., Yadava, V. & Patel, R.K. Design optimization of cubic Bezier horn for ultrasonic machining. Sādhanā 45, 85 (2020). https://doi.org/10.1007/s12046-020-1321-8

Download citation

  • Received:

  • Revised:

  • Accepted:

  • Published:

  • DOI: https://doi.org/10.1007/s12046-020-1321-8

Keywords

Search

Navigation