Harmonic Analysis of Ultrasonic Machining Tool Through Finite Element Method

The conventional machining process is not suitable for machining of hard and fragile materials. To machine such kind of materials, the non-conventional machining process is used. In the modern industry, ultrasonic machining (USM) is used for machining the hard and fragile materials. Ultrasonic tool is a major component of the USM system. In the present study, three different tool profiles, i.e. cylindrical, conical and stepped shaped tools are designed with the help of a commercial software ANSYS workbench. A defect is introduced in the tool in three different orientations, i.e. horizontal, vertical and inclined axis. A comparative study of defective and non-defective tool profiles is experienced. Harmonic analysis is performed to calculate the axial deformation of the defective and non-defective tools. Frequency range is considered as 20,000 Hz - 30,000 Hz in the harmonic analysis. The deformation of the tool profiles is experienced in longitudinal modes. Higher the deformation of the tool, lower the machining efficiency. In the cylindrical and conical tool, the maximum deformation occurred where defect is introduced in the vertical axis. However, in the stepped tool, the maximum deformation occurred where the defect is introduced in the inclined axis. Ultrasonic tool with lower deformation can be used for industrial applications with good machining performance.