The Study of Sonotrode Design for Ultrasonic Surface Burnishing Process by Finite Element Method

Abstract

This research studies the design of a sonotrode for the ultrasonic assist vibration surface polishing. The objective is to study the effects of changing of the total length, shoulder- length, shoulder placement combined with clamping equipment, shoulder radius, and diameter affect to frequency and vibration amplitude when completed stack also. The ultrasonic frequency is generated by a 20 kHz ultrasonic generator connected to a piezoelectric to convert electrical waves into vibrations. The experiment used the finite element method to simulate the natural frequency to select the mode of longitudinal direction and resonance of the entire system corresponds to the frequency from the generator. Frequency response and internal stress to choose and present a design that is suitable for use. Compare with the actual experimental results in AL 7075- T6 sonotrode. The experiment, it was found that the resonance frequency can be adjusted by modified the total length, length of the shoulder distance and radius to making the resonance adjustable. Finite element simulation had a percentage error of 1.11% for the frequency result and 2.14% for the amplitude result. The finite element method is used to simulate the sonotrode shape to reduce material preparation losses and tuning time to determine the properly desired frequency of ultrasonic stack. This research used Computer- aided engineering simulation to predict the frequency response of the dimensional variables of the design by selecting an uncomplicated sonotrode.