Search Results (42)

This study presents the first investigation into the application of ultrasonic vibration-assisted electrical discharge machining (UV-EDM) using graphite electrodes for external cylindrical surface machining—an essential surface in the production of tablet punches and sheet metal-forming dies. A custom ultrasonic horn was designed and fabricated using 90CrSi material to operate effectively at a resonant frequency of 20 kHz, ensuring stable vibration transmission throughout the machining process. A Box–Behnken experimental design was employed to explore the effects of five process parameters—vibration amplitude (A), pulse-on time (Ton), pulse-off time (Toff), discharge current (Ip), and servo voltage (SV)—on two key performance indicators: material removal rate (MRR) and surface roughness (Ra). The optimization process was conducted in two stages: single-objective analysis to maximize MRR while ensuring Ra < 4 µm, followed by a hybrid multi-objective approach combining NSGA-II and the Analytic Hierarchy Process (AHP). The optimal solution achieved a high MRR of 9.28 g/h while maintaining Ra below the critical surface finish threshold, thus meeting the practical requirements for punch surface quality. The findings confirm the effectiveness of the proposed horn design and hybrid optimization strategy, offering a new direction for enhancing productivity and surface integrity in cylindrical EDM applications using graphite electrodes. Full article

An angled single-excitation elliptical vibration system for ultrasonic-assisted machining was developed in this paper, which was composed of a giant magnetostrictive transducer and an angled horn. Based on the continuous boundary conditions between the components, the frequency equation of the angled vibration system was derived, and the resonant frequencies of vibration systems with different angles were theoretically calculated. The finite element method was employed to investigate the impact of varying angles on the resonant frequency, elliptical trajectory, phase difference, and output amplitude of the vibration systems. The electrical impedance of the vibration system and the longitudinal and transverse vibration amplitudes at the end face of the horn were tested experimentally. The results show that the resonant frequency and phase difference in the vibration system decreased, the transverse amplitude of the output elliptical trajectory increased, and the longitudinal amplitude decreased with the increase in the included angle. The elliptical trajectories obtained from the test were generally consistent with the calculated results, and the calculated values of the resonant frequencies of the three angled vibration systems were in good agreement with the experimental test values. Full article

The thin and straight horn of the ultrasonic transducer is located in the center of the thick transducer, so that the tool tip of the ultrasonic vibration turning tool holder cannot be located on the outermost side of the entire tool holder, which leads to the structural interference between the tool holder and the part during turning. In order to solve this problem, this paper proposes a longitudinal-bending elliptical vibration ultrasonic transducer with a bending horn for ultrasonic vibration-assisted cutting (UVAC). The designed transducer can be used for the partial separation continuous high-speed elliptic ultrasonic vibration cutting (HEUVC) of external surface and internal cavity. The ultrasonic vibration amplitude of the transducer can meet the needs of HEUVC. When using an ultrasonic transducer with a bending horn for HEUVC, compared with conventional cutting (CC), HEUVC can improve the tool life by about 50%. Full article

Due to the high hardness and brittleness of sapphire, traditional machining methods are prone to surface scratches and microcracks. As an advanced processing technique, ultrasonic machining can reduce damage to hard–brittle materials and improve surface quality. In this study, an integrated ultrasonic longitudinal–torsional vibration system consisting of both a horn and a tool was designed. The resonant frequency and output amplitude of the horn were simulated and tested. The results indicated that the resonant frequency was 19.857 kHz, the longitudinal amplitude at the tool end was 4.2 µm, and the torsional amplitude was 1.8 µm. Experiments were then carried out to investigate the effects of various machining parameters on the reduction of sapphire surface roughness (Ra) and material removal rate (MRR). A comparative experiment was then conducted to evaluate the effects of ultrasonic longitudinal and longitudinal–torsional vibration on sapphire grinding. The ultrasonic longitudinal–torsional grinding experiments showed that the surface roughness of the sapphire workpiece was reduced from 960.6 nm to 82.6 nm, and the surface flatness was improved to 84.3 nm. Compared with longitudinal ultrasonic vibration, longitudinal torsional grinding reduced the surface roughness of sapphire workpieces by 48% and increased the surface flatness by 88.3%. The results of this study provide specific guidance for the longitudinal–torsional composite ultrasonic machining of hard–brittle materials. Full article

The amplifier rod, also known as a concentrator, is an important component in ultrasonic transducer devices. Its main functions are amplitude amplification and impedance matching, playing a crucial role in ultrasonic machining systems. This article conducts modal analysis and harmonic response analysis of the horn and the tool-added horn, using simulation software, gradually studying the dynamic performance of the catenary linear horn in ultrasonic machining. The optimized frequency of the amplitude rod is obtained, and the effect of the resulting vibration frequency in actual processing is verified through atomization effect tests. The results show that the resonance frequency obtained by finite element analysis has a small error with the actual test, only 0.789%, and magnification error of about 0.165%, which meet the design requirements. It provides reliable design basis and data foundation for the engineering application of the variable rod in ultrasonic machining. Full article

Background/Objectives: Correct supervision during the performance of resistance exercises is imperative to the correct execution of these exercises. This study presents a proposal for the use of Morisita–Horn similarity indices in modelling with machine learning methods to identify changes in positional sequence patterns during the biceps-curl weight-lifting exercise with a barbell. The models used are based on the fuzzy logic (FL) and support vector machine (SVM) methods. Methods: Ten male volunteers (age: 26 ± 4.9 years, height: 177 ± 8.0 cm, body weight: 86 ± 16 kg) performed a standing barbell bicep curl with additional weights. A smartphone was used to record their movements in the sagittal plane, providing information about joint positions and changes in the sequential position of the bar during each lifting attempt. Maximum absolute deviations of movement amplitudes were calculated for each execution. Results: A variance analysis revealed significant deviations (p < 0.002) in vertical displacement between the standard execution and execution with a load of 50% of the subject’s body weight. Experts with over thirty years of experience in resistance-exercise evaluation evaluated the exercises, and their results showed an agreement of over 70% with the results of the ANOVA. The similarity indices, absolute deviations, and expert evaluations were used for modelling in both the FL system and the SVM. The root mean square error and R-squared results for the FL system (R² = 0.92, r = 0.96) were superior to those of the SVM (R² = 0.81, r = 0.79). Conclusions: The use of FL in modelling emerges as a promising approach with which to support the assessment of movement patterns. Its applications range from automated detection of errors in exercise execution to enhancing motor performance in athletes. Full article

Ultrasonic power stimulation of polymers has been employed to modify their properties for various industrial applications. It is used to disperse particles in polymers or to impregnate continuous fiber-reinforced filaments. These processes operate under extreme conditions, involving temperatures exceeding 400 °C and pressures reaching up to 60 bars. Traditional sound introduction systems rely on moving horns within cavities, which pose significant challenges in maintaining clean environments. The moving horn makes it inconceivable to seal such sound introduction systems. To address these limitations, an innovative tool that incorporates only sealed components capable of introducing sound energy without employing cavities was developed. This technology focuses on optimizing eigenfrequencies to efficiently transfer motion into the polymer channel while minimizing disturbing vibrations and sealing issues. The simulation results reveal the mode of operation between the fourth and fifth resonance of the tool. The measurements of the tool validate this theory, indicating a range of operation between 18.5 kHz and 19.5 kHz. With an amplitude of 15 μm, resulting in a minimum power introduction of 224.03 W/cm^² in PLA, the average flow rate gain is 13.6%. This new design reduces the risk of blockages and damage in the processed goods and minimizes the force required to process the polymer. Full article

Tefluthrin (Tef) is categorized as a type-I pyrethroid insecticide, telmisartan (Tel) functions as an angiotensin II receptor blocker, and KB-R7943 has been identified as an inhibitor of the Na⁺-Ca²⁺ exchange process. However, the influence of these compounds on the amplitude and gating properties of voltage-gated Na⁺ current (I_Na) in neurons associated with pain signaling remains unclear. In cultured dorsal root ganglion (DRG) neurons, whole-cell current recordings revealed that Tef or Tel increased the peak amplitude of I_Na, concomitant with an elevation in the time constant of I_Na inactivation, particularly in the slow component. Conversely, exposure to KB-R7943 resulted in a depression in I_Na, coupled with a decrease in the slow component of the inactivation time constant of I_Na. Theoretical simulations and bifurcation analyses were performed on a modeled interneuron in the spinal dorsal horn. The occurrence of I_Na inactivation accentuated the subthreshold oscillations (SO) in the membrane potential. With an increase in applied current, SO became more pronounced, accompanied by the emergence of high-frequency spiking (HS) with a frequency of approximately 150 Hz. Moreover, an elevation in I_Na conductance further intensified both SO and HF. Consequently, through experimental and in silico studies, this work reflects that Tef, Tel, or KB-R7943 significantly impacts the magnitude and gating properties of I_Na in neurons associated with pain signaling. The alterations in I_Na magnitude and gating in these neurons suggest a close relationship with pain transmission. Full article

In this paper, the advantages of the joint use of MHz- and GHz-frequency band impulses when employing contactless ground penetration radar (GPR) for the remote sensing of biomass, the height of the wheat canopy, and underlying soil moisture were experimentally investigated. A MHz-frequency band nanosecond impulse with a duration of 1.2 ns (average frequency of 750 MHz and spectrum bandwidth of 580 MHz, at a level of –6 dB) was emitted and received by a GPR OKO-3 equipped with an AB-900 M3 antenna unit. A GHz-frequency band sub-nanosecond impulse with a duration of 0.5 ns (average frequency of 3.2 GHz and spectral bandwidth of 1.36 GHz, at a level of −6 dB) was generated using a horn antenna and a Keysight FieldFox N9917B 18 GHz vector network analyzer. It has been shown that changes in the relative amplitudes and time delays of nanosecond impulses, reflected from a soil surface covered with wheat at a height from 0 to 87 cm and fresh above-ground biomass (AGB) from 0 to 1.5 kg/m², do not exceed 6% and 0.09 ns, respectively. GPR nanosecond impulses reflected/scattered by the wheat canopy have not been detected. In this research, sub-nanosecond impulses reflected/scattered by the wheat canopy have been confidently identified and make it possible to measure the wheat height (fresh AGB up to 2.3 kg/m² and height up to 104 cm) with a determination coefficient (R²) of ~0.99 and a bias of ~−7 cm, as well as fresh AGB where R² = 0.97, with a bias = −0.09 kg/m², and a root-mean-square error of 0.1 kg/m². The joint use of impulses in two different MHz- and GHz-frequency bands will, in the future, make it possible to create UAV-based reflectometers for simultaneously mapping the soil moisture, height, and biomass of vegetation for precision farming systems. Full article

The use of advanced brittle composites in engineering systems has necessitated robotic rotary ultrasonic machining to attain high precision with minimal machining defects such as delamination, burrs, and cracks. Longitudinal–torsional coupled (LTC) vibrations are created by introducing helical slots to a horn’s profile to enhance the quality of ultrasonic machining. In this investigative research, modified ultrasonic horns were designed for a giant magnetostrictive transducer by generating helical slots in catenoidal and cubic polynomial profiles to attain a high amplitude ratio ($T_A/L_A$) and low stress concentrations. Novel ultrasonic horns with a giant magnetostrictive transducer were modelled to compute impedances and harmonic excitation responses. A structural dynamic analysis was conducted to investigate the effect of the location, width, depth and angle of helical slots on the Eigenfrequencies, torsional vibration amplitude, longitudinal vibration amplitude, stresses and amplitude ratio in novel LTC ultrasonic horns for different materials using the finite element method (FEM) based on the block Lanczos and full-solution methods. The newly designed horns achieved a higher amplitude ratio and lower stresses in comparison to the Bezier and industrial stepped LTC horns with the same length, end diameters and operating conditions. The novel cubic polynomial LTC ultrasonic horn was found superior to its catenoidal counterpart as a result of an $8.45\%$ higher amplitude ratio. However, the catenoidal LTC ultrasonic horn exhibited 1.87% lower stress levels. The position of the helical slots was found to have the most significant influence on the vibration characteristics of LTC ultrasonic horns followed by the width, depth and angle. This high amplitude ratio will contribute to the improved vibration characteristics that will help realize good surface morphology when machining advanced materials. Full article

This study explores the damping effects of ram horn ridges on mechanical impacts resulting from ramming. We measured the amplitudes and frequencies of ridges along the axial (pitch) direction of the ridges of ram horns obtained from eight specimens across six different species. While the horns shared a similar spiral-shaped pattern with surface ridges, our findings show variations among the horns, including ridge spacing and growth trends. Additionally, we employed finite element analysis (FEA) to compare a ridged horn model with a non-ridged counterpart to provide an understanding of the damping characteristics of the surface ridges. Our FEA results reveal that the ridged horn decreased the initial ramming pressure by 20.7%, increased the shear stress by 66.9%, and decreased the axial strain by 27.3%, the radial strain by 16.7%, and the shear strain by 14.3% at a 50 ms impact duration compared to those of the non-ridged horn. The damping ratio was increased by 7.9% because of the ridges. This study elucidates three primary functions of the different species of ram horns’ spirals and ridges: (1) to transfer longitudinal waves into shear waves, (2) to filter shear waves, and (3) to stabilize the structure by mitigating excessive strain. Full article

Ultrasonic welding (USW) of thermoplastics plays a significant role in the automobile industry. In this study, the effect of the welding time on the joint strength of ultrasonically welded acrylonitrile–butadiene–styrene (ABS) and the weld formation mechanism were investigated. The results showed that the peak load firstly increased to a maximum value of 3.4 kN and then dropped with further extension of the welding time, whereas the weld area increased continuously until reaching a plateau. The optimal welding variables for the USW of ABS were a welding time of 1.3 s with a welding pressure of 0.13 MPa. Interfacial failure and workpiece breakage were the main failure modes of the joints. The application of real-time horn displacement into a finite element model could improve the simulation accuracy of weld formation. The simulated results were close to the experimental results, and the welding process of the USW of ABS made with a 1.7 s welding time can be divided into five phases based on the amplitude and horn displacement change: weld initiation (Phase I), horn retraction (Phase II), melt-and-flow equilibrium (Phase III), horn indentation and squeeze out (Phase IV) and weld solidification (Phase V). Obvious pores emerged during Phase IV, owing to the thermal decomposition of the ABS. This study yielded a fundamental understanding of the USW of ABS and provides a theoretical basis and technological support for further application and promotion of other ultrasonically welded thermoplastic composites. Full article

Microbubbles, which are tiny bubbles with a diameter of less than 100 µm, have been attracting attention in recent years. Conventional methods of microbubble generation using porous material and swirling flows have problems such as large equipment size and non-uniform bubble generation. Therefore, we have been developing a hollow ultrasonic horn with an internal flow path as a microbubble-generating device. By supplying gas and ultrasonic waves simultaneously, the gas–liquid interface is violently disturbed to generate microbubbles. Although this device can generate microbubbles even in highly viscous fluids and high-temperature fluids such as molten metals, it has the problem of generating many relatively large bubbles of 1 mm or more. Since the generation of a large amount of microbubbles in a short period of time is required to realize actual applications in agriculture, aquaculture, and medicine, conventional research has tried to solve this problem by increasing the amplitude of the ultrasonic oscillation. However, it is difficult to further increase the amplitude due to the structural reasons of the horn and the behavior of bubbles at the horn tip; therefore, the oscillating area of the tip of the horn, which had not received attention before, was enlarged by a factor of 2.94 times to facilitate the ultrasonic wave transmission to the bubbles, and the effect of this was investigated. As a result, a large number of gases were miniaturized, especially at high gas flow rates, leading to an increase in the amount of microbubbles generated. Full article

As a renewable and sustainable resource, lignocellulosic biomass serves as a crucial raw material for the production of biofuels, biochemicals, and various value-added products. This paper aims to develop and optimize a mild alkaline treatment of sawdust assisted by ultrasound, along with enzymatic hydrolysis of the pretreated material. The alkaline sonochemical pretreatment emerged as the optimal approach to enhance the susceptibility of cellulose to subsequent enzymatic hydrolysis to improve the yield of reducing sugars. A comparative study was performed using various ultrasonic applicators (horn and bath) and conventional assisted alkaline pretreatment. The ultrasonic-assisted pretreatment revealed a higher delignification of 68% (horn) and 57% (bath) compared with conventional pretreatment. Processes were optimized using a statistical analysis based on a 2³ factorial design. The ratios between sawdust and alkaline solution (R_SL = 0.5–1.5 g/100 mL), US amplitude (A = 20–60%), and working temperature (t = 30–50 °C) were selected as process factors. The optimal operating conditions to maximize the reducing sugar yield (138.15 mg GE/g_substrate) were found as follows: a solid/liquid ratio of R_SL,opt = 1.25 g/100 mL, US amplitude of A_opt = 60%, and pretreatment temperature of t_opt = 50 °C. The overall outcomes clearly confirmed the intensification of delignification by ultrasound-assisted alkaline pretreatment. Full article

The design of the resonant ultrasonic vibration-assisted laser cladding (R-UVALC) setup involved employing finite element analysis (FEA) to simulate the ultrasonic transducer, horn, and workpiece in a resonance state. The impact of R-UVALC on AlCrFeMnNi high-entropy alloys was assessed using various ultrasonic vibration amplitudes of 0, 5, 10, and 15 µm, with a constant frequency of 20 kHz. Ultrasonic vibrations reduced pores and cracks and increased the clad breadth, melt pool wetting angle, and laser-clad layer consistency. The columnar elongated grains in proximity to the substrate surface underwent a size reduction and transformed into grains with a more equiaxed shape with the utilization of ultrasonic vibrations at an amplitude of 5 µm. Laser cladding performed without ultrasonic vibrations yields two phases: face-centered cubic (FCC) and body-centered cubic (BCC). However, when the coating is exposed to ultrasonic vibrations with an amplitude of 5 µm, it forms a solitary body-centered cubic (BCC) phase. The microhardness tripled compared to the substrate, and the most significant microhardness value was achieved at 5 µm of ultrasonic vibration. The friction coefficient was assessed at an ambient temperature, revealing that an ultrasonic amplitude yields the lowest friction coefficient, demonstrating the excellent wear resistance properties of the coating. The analysis of the 3D surface profile of the wear indicates that the use of ultrasonic aid with a 5 µm amplitude leads to reduced depth of scars, and the primary wear mechanism observed is abrasive and oxidative wear with fewer grooves and debris. In addition, XPS analysis revealed the presence of metal components in an oxidized condition, suggesting that the wear process is oxidative in nature. Integrating the R-UVALC setup into a resonance state can significantly enhance the efficiency of the laser cladding process in the laser cladding field. Full article