Ultrasonic Honeycomb Core Holder With Modular High-Amplitude Cutting
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Solution Overview
Problem
The design of ultrasonic cutting holders for honeycomb cores faces challenges in achieving large amplitude output, leading to size and weight issues, complex structures, and high manufacturing costs, which hinder their applicability and interchangeability on universal machine tools, affecting machining efficiency and safety.
Innovation Solution
The ultrasonic cutting holder design incorporates a swing mechanism, transducer, first-stage and second-stage amplitude transformers, and an ultrasonic power transmission mechanism with a compact layout and cooling system, featuring a stepped shaft structure, vibration isolation grooves, and a detachable second-stage amplitude transformer for easy tool changes, reducing size and weight while ensuring efficient power transmission and heat management.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If traditional ultrasonic holder design with transducer, first-stage amplitude transformer and second-stage amplitude transformer is used, then large amplitude output is achieved, but the holder becomes large in size and heavy in weight
Solution Approach 1:
The holder is divided into modular components: a standard interface portion for machine tool mounting, a swing mechanism with bearing support, and an interchangeable ultrasonic vibration system portion. This segmentation allows the heavy amplitude-transforming components to be separated from the main holder body, reducing the weight of the moving portion while maintaining large amplitude output capability through modular assembly.
Solution Approach 2:
The patent introduces a swing mechanism that allows the ultrasonic cutter to oscillate in a circular arc path rather than purely linear motion. This dimensional change from linear to arc-based ultrasonic vibration enables the system to achieve large effective cutting amplitude while using a more compact holder structure, thereby reducing overall holder size and weight.
2Power
If traditional ultrasonic holder design with three parts (transducer, first-stage amplitude transformer, second-stage amplitude transformer) is used, then large amplitude ultrasonic output is achieved, but the holder structure becomes complex
Solution Approach 1:
The holder structure is segmented into a fixed standard interface portion and an interchangeable ultrasonic vibration system portion. The complex amplitude-transforming components (transducer and amplitude transformers) are consolidated into a self-contained ultrasonic cutter assembly that can be quickly swapped, simplifying the main holder structure while preserving large amplitude output capability in the modular portion.
Solution Approach 2:
The patent employs a swing mechanism with bearing support that enables dynamic circular arc motion of the ultrasonic cutter. This dynamic design replaces static multi-stage amplitude transformation with a moving system that achieves large amplitude through controlled oscillation in arc path, thereby simplifying the overall holder structure while maintaining ultrasonic output performance.
3Manufacturing precision
If ultrasonic cutting holder with large amplitude output is designed, then machining quality is improved, but the holder size increases reducing effective travel of machine tool
Solution Approach 1:
The swing mechanism transforms linear ultrasonic vibration into circular arc motion, allowing the cutting edge to traverse a larger effective path amplitude without increasing the axial length of the holder. This dimensional transformation enables high machining quality through large arc-based amplitude while keeping the holder compact enough to preserve machine tool effective travel.
Solution Approach 2:
By separating the ultrasonic vibration system into an interchangeable modular portion, the patent allows the main holder body to remain compact for machine tool compatibility, while the modular ultrasonic cutter portion contains the amplitude-generating mechanisms. This segmentation enables large amplitude output in the cutting portion without proportionally increasing the overall holder length that would interfere with machine tool travel.
4Manufacturing precision
If ultrasonic cutting holder with large amplitude output is designed, then machining quality is improved, but the holder weight increases exceeding bearing capacity of machine tool spindle
Solution Approach 1:
The holder is divided into a stationary standard interface portion mounted on the machine tool spindle and a movable ultrasonic vibration system portion containing the transducer and amplitude transformers. This segmentation concentrates the weight of amplitude-generating components in the interchangeable cutter portion, which can be optimized for ultrasonic vibration rather than supporting full holder weight, thereby reducing the effective weight burden on the machine tool spindle while maintaining large amplitude output capability.
Solution Approach 2:
The swing mechanism enables the ultrasonic cutter to move dynamically in a circular arc path during cutting operations. This dynamic motion distributes the effective cutting force and amplitude generation over the arc trajectory rather than requiring the entire holder mass to be accelerated linearly, effectively reducing the inertial weight impact on the machine tool spindle while achieving large amplitude cutting action.
5Stability of the object's composition
If ultrasonic cutting holder is designed as integrated structure, then structural stability is ensured, but tool change requires replacing whole holder increasing tool change time
Solution Approach 1:
The holder is segmented into a permanent standard interface portion that remains mounted on the machine tool providing stable mounting reference, and an interchangeable ultrasonic vibration system portion containing the cutter and amplitude-transforming components. This segmentation allows only the cutting tool portion to be changed while retaining the stable interface structure, significantly reducing tool change time while preserving structural stability during operation.
Solution Approach 2:
The standard interface portion is designed with universal mounting features (tapered bore, set screws) that can accommodate different ultrasonic cutter assemblies while maintaining consistent positioning and stability. This universal interface allows rapid tool changes between different cutting tools without requiring replacement of the entire holder, reducing tool change time while ensuring structural stability through the standardized mounting system.
6Manufacturing precision
If different ultrasonic cutting tools correspond to different ultrasonic cutting holders, then each tool is optimized for its specific application, but manufacturing cost increases
Solution Approach 1:
The system is segmented into a single standardized holder body that serves as a common platform, and multiple interchangeable ultrasonic cutter assemblies optimized for different cutting applications. This segmentation allows the expensive amplitude-transforming components to be consolidated into modular cutter units that can be manufactured and optimized independently, then attached to the same holder body. This approach enables tool optimization for different applications while sharing the common holder infrastructure, thereby reducing overall manufacturing cost compared to designing complete integrated holders for each tool type.
Solution Approach 2:
The holder body is designed with universal features (standard interface, swing mechanism, bearing support) that can accommodate multiple types of ultrasonic cutting tools. This universality allows a single holder design to support various optimized cutter assemblies for different cutting applications, eliminating the need to manufacture multiple specialized holder variants and thereby reducing manufacturing costs while maintaining tool-specific optimization capabilities.
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
This design enhances the interchangeability and automation of ultrasonic cutting holders, reduces manufacturing costs, and improves machining efficiency by minimizing tool change time and ensuring precise cutting with reduced tool wear and chip discharge issues, making ultrasonic cutting more viable for honeycomb core materials.
Implementation Method 1
a transducer, a first-stage amplitude transformer... the transducer includes an inner-cooling preload bolt with a hollow structure, a back shroud and an annular ceramic chip group
Implementation Method 2
first-stage amplitude transformer, a second-stage amplitude transformer... the outer wall of the holder shell is in a shape of stepped shaft
Implementation Method 3
a special internal cooling structure needs to be designed... the holder standard interface is provided with a holder center cooling hole extending to the small shaft segment
Data Source
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AI summary
The present disclosure discloses an ultrasonic cutting holder for a honeycomb core, including a holder, a swing mechanism, a transducer, a first-stage amplitude transformer, a second-stage amplitude transformer, an ultrasonic cutting tool, and an ultrasonic power transmission mechanism. The present disclosure provides an ultrasonic cutting holder for a honeycomb core with large amplitude output capacity and considering the interchangeability requirements among different vibration systems, which solves the problem of the applicability of ultrasonic cutting holder on the universal machine tool and improves the automation level of ultrasonic cutting.