Design of a contactless powered and piezoelectric-actuated tool for non-resonant low-frequency vibration-assisted machining of brittle-hard materials

Abstract Ultrasonic-assisted grinding (UAG) is the state-of-the-art process for machining of brittle-hard materials. In comparison to conventional processes, main advantages lie in reduction tool wear and forces. Such a vibration system based on resonant actuator power supply unit generating alternating current. Both units are interconnected by contactless energy transfer (CET) system. This configuration shows one optimal working point at frequency with maximum amplitude, which significantly depending shape. this work, piezo-activated designed realize non-resonant low-frequency vibrations. Major emphasis put thermal behavior piezo drive, particularly in-process heating frequency. addition, focus lays theoretical numerical design radial operating transducer CET previously set design. As result, offers fully variable adjustment amplitude from under 1 over 50 μm range. Outside range, higher amplitudes can be achieved short periods detriment fatigue strength according FKM.