Methods for reducing cutting temperature in ultrasonic cutting of bone

Ultrasonic cutting is widely used in food processing applications to produce a clean and accurate cut. However, it is yet to be adopted as an instrument of choice in orthopaedic applications, mainly due to the high temperatures that can be generated at the cut site and the consequent requirement to use additional cooling. For example, if cutting temperatures above 55-60 degrees C are reached, particularly for sustained periods, bone necrosis can occur, compromising post-operative recovery. A recent study by the authors has shown that the thermal response in natural materials, such as wood and bone, is affected by the absorption of ultrasonic energy and conduction of heat from the cut site. In this paper the dependency of cutting parameters, such as blade tip vibration velocity, applied load, tuned frequency and coupling contact conditions, on the thermal response are reported and results show that it is possible to maintain cutting temperatures within safety limits by controlling the cutting parameters. A novel cutting blade design is proposed that reduces frictional heat generated at the cut site. Through a series of experimental investigations using fresh bovine femur it is demonstrated that the cutting temperature, and hence thermal damage, can be reduced by selecting appropriate cutting parameters and blade profile.     

Ultrasonic excitation affects friction interactions between food materials and cutting tools

In the food industry, ultrasonic cutting is used to improve separation by a reduction of the cutting force. This reduction can be attributed to the modification of tool–workpiece interactions at the cutting edge and along the tool flanks because of the superposition of the cutting movement with ultrasonic vibration of the cutting tool. In this study, model experiments were used to analyze friction between the flanks of a cutting tool and the material to be cut. Friction force at a commercial cutting sonotrode was quantified using combined cutting–friction experiments, and sliding friction tests were carried out by adapting a standard draw-off assembly and using an ultrasonic welding sonotrode as sliding surface. The impact of material parameters, ultrasonic amplitude, and the texture of the contacting food surface on friction force was investigated. The results show that ultrasonic vibration significantly reduces the sliding friction force. While the amplitude showed no influence within the tested range, the texture of the contact surface of the food affects the intensity of ultrasonic transportation effects. These effects are a result of mechanical interactions and of changes in material properties of the contact layer, which are induced by the deformation of contact points, friction heating and absorption heating because of the dissipation of mechanical vibration energy.     

A high power ultrasonic array based test cell

This paper describes the use of finite element (FE) analysis as a tool in the design process for laboratory based ultrasonic test cells. The system was designed to incorporate an array of ultrasonic transducers to provide a pressure focus in the centre of the cell and importantly, operate both above and below the cavitation threshold of the load medium. Furthermore, the cell incorporates a coolant jacket to accommodate temperature control of the load material associated with the process. A 2D FE model corresponding to a slice through the operational plane of the cell was developed and used to investigate the influence of cell wall material and thickness, transducer configuration, rotation of a metallic stirrer blade and heat transfer fluid on the cell acoustic response. Importantly, experimentally measured pressure field maps demonstrate good correlation with the FE predicted fields. A final manufactured test cell is shown to produce a highly focussed region of cavitation. Finally, the importance in accurately representing the acoustic properties of the constituent materials used in such FE models is demonstrated through an illustrated example.     

Theoretical and experimental investigations on rotary ultrasonic surface micro-machining of brittle materials

Many brittle materials, such as single-crystal materials, amorphous materials, and ceramics, are widely used in many industries such as the energy industry, aerospace industry, and biomedical industry. In recent years, there is an increasing demand for high-precision micro-machining of these brittle materials to produce precision functional parts. Traditional ultra-precision micro-machining can lead to workpiece cracking, low machined surface quality, and reduced tool life. To reduce and further solve these problems, a new micro-machining process is needed. As one of the nontraditional machining processes, rotary ultrasonic machining is an effective method to reduce the issues generated by traditional machining processes of brittle materials. Therefore, rotary ultrasonic micro-machining (RUμM) is investigated to conduct the surface micro-machining of brittle materials. Due to the small diameter cutting tool (<500 μm) and high accuracy requirements, the impact of input parameters in the rotary ultrasonic surface micro-machining (RUSμM) process on tool deformation and cutting quality is extremely different from that in rotary ultrasonic surface machining (RUSM) with relatively large diameter cutting tool (∼10 mm). Up till now, there is still no investigation on the effects of ultrasonic vibration (UV) and input variables (such as tool rotation speed and depth of cut) on cutting force and machined surface quality in RUSμM of brittle materials. To fill this knowledge gap, rotary ultrasonic surface micro-machining of the silicon wafer (one of the most versatile brittle materials) was conducted in this study. The effects of ultrasonic vibration, tool rotation speed, and depth of cut on tool trajectory, material removal rate (MRR), cutting force, cutting surface quality, and residual stress were investigated. Results show that the ultrasonic vibration could reduce the cutting force, improve the cutting surface quality, and suppress the residual compressive stress, especially under conditions with high tool rotation speed.     

Effect of thermal stresses on chip-free diode laser cutting of glass

In laser cleaving of brittle materials using controlled fracture technique, thermal stresses are used to induce a crack and the material is separated along the cutting path by extending this crack. In this study, a glass sheet is stressed thermally using a 808-940 nm diode laser radiation. One of the problems in laser cutting of glass with controlled fracture technique is the cut deviation at the leading and the trailing edges of the glass sheet. In order to avoid this damage it is necessary to understand the stress distributions which control crack propagation. A study is conducted here to analyse the cut deviation problem of glass by examining the stress fields during diode laser cutting of soda-lime glass sheets. Optical microscope photographs of the breaking surface are obtained to examine the surface quality and cut path deviation while the latter is explained from the results of the stress fields which are obtained from a finite element simulation.     

Cleaved end-face quality of microstructured polymer optical fibres

The cutting of a microstructured polymer optical fibre to form an optical end-face is studied. The effect of the temperature and speed of the cutting blade on the end-face is qualitatively assessed and it is found that for fibres at temperatures in the range 70-90 °C, a blade at a similar temperature moving at a speed of less than 0.5 mm/s produces a good quality end-face. The nature of the damage caused by the cutting process was examined and found to vary with fibre temperature, blade quality and cut depth. Thermo-mechanical analysis showed that the drawn material was significantly more visco-elastic than the annealed raw material in the 70-90 °C temperature range. The behaviour of the surface damage with cut depth was found to be consistent with the behaviour of a visco-elastic material.     

Rotary ultrasonic machining of CFRP: A mechanistic predictive model for cutting force

Cutting force is one of the most important output variables in rotary ultrasonic machining (RUM) of carbon fiber reinforced plastic (CFRP) composites. Many experimental investigations on cutting force in RUM of CFRP have been reported. However, in the literature, there are no cutting force models for RUM of CFRP. This paper develops a mechanistic predictive model for cutting force in RUM of CFRP. The material removal mechanism of CFRP in RUM has been analyzed first. The model is based on the assumption that brittle fracture is the dominant mode of material removal. CFRP micromechanical analysis has been conducted to represent CFRP as an equivalent homogeneous material to obtain the mechanical properties of CFRP from its components. Based on this model, relationships between input variables (including ultrasonic vibration amplitude, tool rotation speed, feedrate, abrasive size, and abrasive concentration) and cutting force can be predicted. The relationships between input variables and important intermediate variables (indentation depth, effective contact time, and maximum impact force of single abrasive grain) have been investigated to explain predicted trends of cutting force. Experiments are conducted to verify the model, and experimental results agree well with predicted trends from this model.     

Longitudinal ultrasonic vibration assisted guillotining of stacked paper

Ultrasonic vibration assisted cutting is a complex process with high dynamics. The interaction between cutting tool and workpiece is of key interest to understand the entire process. Experimental investigations are limited by the dynamics of the measurement system, and thus appropriately modeling of the ultrasonic vibration assisted cutting process is essential. In this investigation, a dynamic model regarding the ultrasonic vibration assisted guillotining of stacked paper sheets is developed. A Kelvin–Voigt material model, representing the individual sheets, is chosen, with its stiffness and damping parameters being empirically determined. A novel measurement strategy for studying the contact time and interaction between cutting tool and workpiece is introduced. It allows the verification of the highly dynamic behavior of the developed model. With the dynamic model, the experimentally observed cutting forces can be calculated. It is found that the dynamic forces cause a quicker failure of the material, which leads to a lower compression of the stack prior to reaching the critical cutting force.     

Modelling the attenuation in the ATHENA finite elements code for the ultrasonic testing of austenitic stainless steel welds

Multipass welds made in austenitic stainless steel, in the primary circuit of nuclear power plants with pressurized water reactors, are characterized by an anisotropic and heterogeneous structure that disturbs the ultrasonic propagation and makes ultrasonic non-destructive testing difficult. The ATHENA 2D finite element simulation code was developed to help understand the various physical phenomena at play. In this paper, we shall describe the attenuation model implemented in this code to give an account of wave scattering phenomenon through polycrystalline materials. This model is in particular based on the optimization of two tensors that characterize this material on the basis of experimental values of ultrasonic velocities attenuation coefficients. Three experimental configurations, two of which are representative of the industrial welds assessment case, are studied in view of validating the model through comparison with the simulation results. We shall thus provide a quantitative proof that taking into account the attenuation in the ATHENA code dramatically improves the results in terms of the amplitude of the echoes. The association of the code and detailed characterization of a weld’s structure constitutes a remarkable breakthrough in the interpretation of the ultrasonic testing on this type of component.     

Numerical simulation of laser-generated ultrasound in non-metallic material by the finite element method

The use of a pulsed laser for the generation of the elastic waves in non-metallic materials in the thermoelastic regime is investigated by using finite element method (FEM), taking into account not only thermal diffusion and the finite spatial and temporal shape of the laser pulse, but also optical penetration and the temperature dependence of material properties. The optimum finite element model is established based on analysis of two important parameters, meshing size and time step, and the stability of solution. Temperature distributions and temperature gradient fields in non-metallic material for different time steps are obtained, this temperature field is equivalent to a bulk force source to generate ultrasonic wave. The laser-generated ultrasound waveforms at the epicenter and surface acoustic waveforms (SAWs) are obtained and the influence of optical penetration into the material on the temperature field and the ultrasound waveforms are analyzed. The numerical results indicate that the heat penetration into non-metallic material is caused mainly by the optical penetration, and the ultrasound waveforms, especially the shape of the precursor, are strongly dependent on the optical penetration depth into non-metallic material.     

用于铝板缺陷无损检测的激光超声有限元模拟研究

激光超声技术能够在材料表面形成超声波，是实现材料缺陷无损检测的重要环节。借助Abaqus有限元分析工具，基于激光超声热弹机制建立了轴对称铝板的表面缺陷模型，模拟了激光激发产生的表面波在材料中的传播特性及其与铝板缺陷的相互作用过程。数值模拟实验表明，铝板表面缺陷的分布深度值越大，反射波越强，并且当缺陷深度达到一定程度时，反射波的幅值趋于稳定；但缺陷的分布宽度对于反射波的影响则十分有限。所得结论为基于激光超声的材料缺陷的定量检测及识别提供有效的理论依据。     

Numerical simulation and experimental validation of ultrasonic de-icing system for wind turbine blade

It is widely accepted that wind energy is clean and renewable. However, icing on the blade surfaces of wind turbines is a serious problem in cold regions, which greatly affects its performance. Therefore, it is important to prevent ice accumulation on the surface of wind turbine blade and remove it whenever necessary. In this paper, a new non-thermal method–ultrasonic de-icing for wind turbine blade is proposed. Firstly, baced on the theory of ultrasonic de-icing, the harmonic analysis of the structure of the composite plate-ice layered system is investigated using the finite element method. The simulation results showed that ultrasonic de-icing method is feasible for wind turbine blade de-icing purposes. Secondly, the de-icing experiment of wind turbine blades using piezoelectric actuators is carried out in the freezer at a temperature of −15 °C, results showed that the ice layer can be debonded from the surface of wind turbine blade by the commonly used piezoelectric transducers made by PZT-5. The optimal frequency of ultrasonic de-icing of wind turbine blade is also given; finally, the installation way of ultrasonic transducers on the inner surface of wind turbine blade is given.     

Laser cutting of thick sheet metals: Residual stress analysis

Laser cutting of tailored blanks from a thick mild steel sheet is considered. Temperature and stress field in the cutting sections are modeled using the finite element method. The residual stress developed in the cutting section is determined using the X-ray diffraction (XRD) technique and is compared with the predictions. The structural and morphological changes in the cut section are examined using the optical microscopy and scanning electron microscopy (SEM). It is found that temperature and von Mises stress increase sharply in the cutting section, particularly in the direction normal to the cutting direction. The residual stress remains high in the region close to the cutting section.     

Three-dimensional finite element simulation of closed delaminations in composite materials

Early stage delaminations in composite materials tend to be closed at rest. Inspection with traditional linear ultrasonic techniques generally fails to diagnose and locate such imperfections. However, if undetected and left untreated, incipient defects may gradually grow within the material and eventually lead to failure of the component. Kissing bonds or clapping contacts inherently demand a non-linear diagnostic method, applying a finite excitation amplitude that is able to overcome an activation threshold to open and close the contact. In order to obtain a better understanding and analysis of the macroscopic non-linear behavior that can be observed at the component level, we developed and investigated the results of a finite element model for a composite material containing a single circular delamination. The model makes use of local node splitting and the non-linear constitutive behavior is implemented by means of spring-damper elements at the delamination interface. The results of this parametric study allow a better insight in the behavior of the excited delamination in experimental conditions, including the appearance of localized subharmonics and harmonics of the excitation frequency. Based on the developed model, two different detection and localization techniques (using either a single frequency or a sweep excitation) were demonstrated to determine position, shape, depth and orientation of one or multiple delaminations.     

The effect of material thickness,laser power and cutting speed on cut path deviation in high-power diode laser chip-free cutting of glass

In the laser cleaving of brittle materials, using controlled fracture technique, thermal stresses are used to induce the crack and the material is separated along the cutting path by extending the crack. One of the problems in laser cutting of glass with this technique is the cut path deviation at the leading and the trailing edges of the glass sheet. Previous work has shown this deviation to be partly due to the high magnitudes of thermal stresses generated near the edges of the sheet. This paper reports on the experimental results of the effects of glass thickness, laser power and the cutting speed on cut path deviation in diode laser cutting of glass. Finite element modelling of the cutting process has also been used to simulate the transient effects of the moving beam and predict thermal fields and stress distributions. These predictions are validated against the experimental data and are used to explain the process mechanisms. It is shown that an increase in the thickness of the glass sheet for the same power and cutting speed or an increase in the cutting speed with constant power and a given sheet thickness results in smaller cut path deviations at the leading and trailing edges of the glass sheet.     

Autoresonant control of nonlinear mode in ultrasonic transducer for machining applications

Experiments conducted in several countries have shown that the improvement of machining quality can be promoted through conversion of the cutting process into one involving controllable high-frequency vibration at the cutting zone. This is achieved through the generation and maintenance of ultrasonic vibration of the cutting tool to alter the fracture process of work-piece material cutting to one in which loading of the materials at the tool tip is incremental, repetitive and controlled. It was shown that excitation of the high-frequency vibro-impact mode of the tool-workpiece interaction is the most effective way of ultrasonic influence on the dynamic characteristics of machining. The exploitation of this nonlinear mode needs a new method of adaptive control for excitation and stabilisation of ultrasonic vibration known as autoresonance. An approach has been developed to design an autoresonant ultrasonic cutting unit as an oscillating system with an intelligent electronic feedback controlling self-excitation in the entire mechatronic system. The feedback produces the exciting force by means of transformation and amplification of the motion signal. This allows realisation for robust control of fine resonant tuning to bring the nonlinear high Q-factor systems into technological application. The autoresonant control provides the possibility of self-tuning and self-adaptation mechanisms for the system to keep the nonlinear resonant mode of oscillation under unpredictable variation of load, structure and parameters. This allows simple regulation of intensity of the process whilst keeping maximum efficiency at all times. An autoresonant system with supervisory computer control was developed, tested and used for the control of the piezoelectric transducer during ultrasonically assisted cutting. The system has been developed as combined analog-digital, where analog devices process the control signal, and parameters of the devices are controlled digitally by computer. The system was applied for advanced machining of aviation materials.     

Laser cutting of holes in thick sheet metals: Development of stress field

Laser cutting of hole in a mild steel thick sheet metal is investigated. Temperature and stress fields developed around the cutting section are simulated using the finite element method. An experimental is carried out accommodating the simulation parameters. The residual stress developed in the cutting section is measured using the XRD technique and findings are compared with the predictions. Optical microscopy and SEM are carried out to examine the morphological changes in the cutting sections. It is found that temperature decays sharply in the region of the laser heat source, which results in high temperature gradient in this region. This causes the development of high stress levels around the cut edges. The residual stresses predicted are in agreement with the measured results.     

Lumped parameter model for multimode laser cutting

A lumped parameter mathematical model is developed to relate the cut depth to the laser cutting parameters and material properties. The model takes into account the threshold power of the incident laser beam for the initiation of cutting and modifies an earlier cutting model so that it applies to a wide set of process parameters ranging from low to high laser powers and slow to fast cutting speeds. Plain steel is taken as an example to show the effects of various process parameters such as the laser power, spot size and cutting speed on the cut depth. Special emphasis is given to the effect of laser mode structure on its cutting capability.     

Simulation of the behavior of the cutting force during ultrasonic rotary machining of materials using structure-time fracture mechanics

An analytical model is developed for the behavior of the cutting force during ultrasonic rotary polishing, and it is based on the concepts of dynamic fracture mechanics and the solution to the problem of impact surface fracture. The dependence of the threshold fracture energy obtained in the problem of erosion using a structure-time approach is used to construct the cutting force model. The dependences of the cutting force on the material feed rate and the rate of tool rotation are obtained, and the developed model is shown to be efficient to explain the effects observed in experiments.     

Laser cutting of Kevlar laminates and thermal stress formed at cutting sections

Laser cutting of Kevlar laminates is carried out and thermal stress field developed in the cutting region is predicted using the finite element code. Temperature predictions are validated through the thermocouple data. The morphological changes in the cutting section are examined by incorporating optical and scanning electron microscopes. It is found that temperature predictions agree well with the thermocouple data. High values of von Mises stress are observed at the cutting edges and at the mid-thickness of the Kevlar laminate due to thermal compression formed in this region. The laser cut edges are free from whiskers; however, striation formation and some small sideways burning is observed at the kerf edges.