Lateral-Projection Sonotrode for Ultrasonic Deburring of Recesses
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Solution Overview
Problem
Conventional sonotrodes struggle to effectively deburr workpieces with complex geometries, such as those featuring openings, bores, and undercuts, due to difficulty in positioning and coupling ultrasonic waves into these areas.
Innovation Solution
A sonotrode design with a main body section and a machining section that extends transversely to the longitudinal axis, allowing insertion into recesses and undercuts, combined with a device that includes an alignment unit for precise positioning, enabling effective ultrasonic deburring of complex geometries.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If conventional sonotrodes are used, then simple geometries can be deburred effectively, but complex geometries with openings, bores, and undercuts cannot be accessed
Solution Approach 1:
The sonotrode is divided into a main body section and a separate machining section that can be coupled to it. The machining section contains the lateral machining projections that can be inserted into recesses, while the main body section contains the coupling for the ultrasonic transducer. This segmentation allows the machining section to access complex geometries while the main body provides stable coupling.
Solution Approach 2:
The machining section includes lateral machining projections that extend substantially transversely to the longitudinal axis of the main body section. This transverse extension allows the machining section to be inserted laterally into recesses, undercuts, and bores of complex geometries, providing access from a different spatial dimension rather than only from the end of the sonotrode.
2Adaptability or versatility
If conventional sonotrode geometries are used, then positioning relative to workpiece surfaces is straightforward, but access to hidden areas in complex geometries is insufficient
Solution Approach 1:
By separating the sonotrode into a main body section and a machining section with lateral projections, the system can position the machining section precisely into recesses while the main body remains externally accessible for coupling and control.
Solution Approach 2:
The machining section acts as an intermediary between the main body section and the hidden areas of the workpiece. It transmits ultrasonic vibrations from the main body into the liquid medium within recesses, enabling access to areas that would otherwise be unreachable.
3Reliability
If ultrasonic waves are coupled into liquid medium, then cavitation occurs effectively, but coupling into recesses of complex geometries is difficult
Solution Approach 1:
The lateral machining projections extend transversely to the longitudinal axis, allowing them to be inserted into recesses from the side rather than requiring end-on coupling. This enables ultrasonic wave coupling into liquid medium within complex geometries while maintaining effective cavitation.
Solution Approach 2:
The machining section is specifically designed with lateral projections that can be inserted into recesses, creating localized ultrasonic coupling points within complex geometries. This allows cavitation to occur effectively in specific hidden areas without requiring the entire sonotrode to be repositioned.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables efficient deburring of workpieces with complex geometries by allowing ultrasonic waves to reach hidden burrs, improving accessibility and effectiveness compared to conventional sonotrodes.
Implementation Method 1
a main body section defining a longitudinal axis and configured to vibrate along the longitudinal axis with, in particular longitudinal, ultrasonic vibrations; an ultrasonic transducer configured to provide the ultrasonic vibrations
Implementation Method 2
The ultrasonic vibrations can induce cavitation in the liquid medium. Cavitation is the formation and dissolution of vapor-filled cavities (vapor bubbles) in liquids. The continuous alternation of higher and lower pressure ranges, for example caused by ultrasonic vibrations, can cause the vapor pressure of the liquid to drop locally. This leads to the spontaneous formation of vapor bubbles. If the ambient pressure increases, the vapor bubbles shrink and can implode, generating additional shock waves in the liquid.
Implementation Method 3
If the ambient pressure increases, the vapor bubbles shrink and can implode, generating additional shock waves in the liquid. If these shock waves encounter a solid surface, any burrs present on the surface of the workpiece to be deburred can be blasted off.
Data Source
Figure 1~2
Figure 3
Figure 4~5
AI summary
The present invention relates to a sonotrode (10) for a device (100) for deburring a workpiece (12) with ultrasonic waves, wherein the sonotrode (10) comprises: - a main body section (14) which defines a longitudinal axis (16) and is configured to vibrate along the longitudinal axis (16) with, in particular longitudinal, ultrasonic vibrations, - a coupling section (18) which can be coupled to an ultrasonic transducer (20) of the device (100), wherein the ultrasonic transducer (20) is configured to provide the ultrasonic vibrations, wherein ultrasonic vibrations coupled via the coupling section (18) can be transmitted to the main body section (14), and - a processing section (22) for emitting the ultrasonic waves for deburring the workpiece (12), wherein the processing section (22) is connected to the main body section (14).wherein the machining section (22) is formed with at least one machining projection (24) which extends from the main body section (14) substantially transversely to the longitudinal axis (16), and wherein the machining section (22), in particular the at least one machining projection (24), is designed to be inserted laterally into a recess (25) of the workpiece (12) to be machined for deburring.