Iranian Journal of Manufacturing Engineering

Iranian Journal of Manufacturing Engineering

Designing and manufacturing of the ultrasonic cutting tools for cutting of polymeric based composites

Document Type : Original Article

Authors
Saba Javadian 1
Mohammad Moradi 1
Aminollah Mohammadi 2
Peiman Mosaddegh 3
1 BSc Student, Department of Mechanical Engineering, Isfahan University of Technology, Isfahan, Iran
2 Assistant Professor, Department of Mechanical Engineering, Isfahan University of Technology, Isfahan, Iran
3 Associate Professor, Department of Mechanical Engineering, Isfahan University of Technology, Isfahan, Iran
10.22034/ijme.2024.442180.1928
Abstract
Characteristics such as excellent mechanical properties, high heat resistance, corrosion resistance and low density have made composites like carbon fiber widely used in various industries including medical, aerospace and automotive. However, due to characteristics such as poor thermal conductivity, low cutting surface quality and high strength, it is difficult to cut it using conventional methods. The aim of this article is to design and build a type of cutting tool that uses ultrasonic waves to reduce the cutting force and improve the cutting surface quality of carbon fiber workpieces. In this research, the design and construction of the horn part of the cutting tool is specifically discussed. First, a stepped horn is designed by performing analytical calculations, and then by adding a conical part with different angles to it, the effect of changing the angle on the amplitude amplification, modal spacing and stress distribution has been investigated by finite element simulation method.The results of numerical simulation show the insignificant effect of changing the angle of the conical part on the result. Finally, the optimized design is built.The results of experimental tests show that the use of ultrasonic waves has a significant effect in reducing the cutting force up to one-sixteenth and significantly improving the quality and straightness of the cutting edge of the carbon fiber workpiece compared to the case without ultrasonic assistance.
Keywords
Ultrasonic Cutting Tools
Horn
Modal Analysis
Numerical Simulation
Carbon Fiber
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