Ultrasonic Spindle Flexible Hinge for Pre-Pressure and Rigidity
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Solution Overview
Problem
Conventional ultrasonic machining techniques face challenges in machining brittle materials due to complex designs and lack of pre-pressure in ultrasonic vibrators, which restricts design flexibility and radial rigidity, making it difficult to effectively transmit vibrations to working tools.
Innovation Solution
A spindle with a flexible hinge and elastic clamping unit that provides adjustable pre-pressure and increased design flexibility, allowing for the transmission of high-frequency micro-vibrations to working tools, enhancing axial and radial rigidity, and enabling machining of brittle materials like semiconductors, ceramics, and glass.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If the ultrasonic vibrator is connected only to the supporting born (not directly to the rotor), then the structure is simpler, but the pre-pressure cannot be adjusted and radial rigidity is insufficient
Solution Approach 1:
The patent introduces an elastic clamping unit as an intermediary component between the ultrasonic vibrator and the rotor. This elastic clamping unit includes clamping elements that can be elastically deformed to provide adjustable pre-pressure to the ultrasonic vibrator, while the flexible hinge serves as a mediator to transmit vibration and maintain radial rigidity. This resolves the contradiction by adding a functional intermediary that enables pre-pressure adjustment without overly complicating the overall structure.
Solution Approach 2:
The patent employs dynamic elements including the elastic clamping unit with movable clamping elements and the flexible hinge with slots that allow controlled deformation. The elastic clamping unit can dynamically adjust its clamping force through the flexible hinge, enabling real-time pre-pressure adjustment while maintaining structural integrity and radial rigidity during operation.
2Productivity
If the ultrasonic vibrator length is set to 1/2 wavelength, then the ultrasonic vibration efficiency is maximized, but the design flexibility is restricted
Solution Approach 1:
The flexible hinge with slots enables the supporting born to dynamically adapt its structure during operation. The slots allow controlled deformation that can compensate for variations in ultrasonic vibrator length, enabling effective ultrasonic vibration even when the vibrator length does not precisely match 1/2 wavelength requirements, thus maintaining design flexibility while preserving vibration efficiency.
Solution Approach 2:
The patent allows for parameter changes in the supporting born structure through the flexible hinge mechanism. By enabling controlled deformation and adjustment in the supporting born, the system can adapt to different ultrasonic vibrator configurations and lengths, freeing the design from the strict 1/2 wavelength constraint while maintaining effective ultrasonic vibration transmission.
3Speed
If the loose flange is used to guide vibration, then the axial direction vibration is improved, but the radial rigidity is not sufficiently strengthened
Solution Approach 1:
The patent merges the functions of vibration guidance and radial support by integrating the flexible hinge with the supporting born structure. The flexible hinge not only guides axial vibration like the loose flange but also provides enhanced radial rigidity through its rigid supporting born connection, combining both functions into a unified structure that performs both tasks effectively.
Solution Approach 2:
The supporting born with flexible hinge creates a composite structural system that combines flexible elements (slots for deformation) with rigid elements (supporting born body). This composite structure simultaneously provides axial vibration guidance through the flexible hinge and enhanced radial rigidity through the rigid supporting born, achieving both functions that the loose flange alone could not provide.
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
The solution enables efficient machining of brittle materials by providing adjustable pre-pressure and enhanced radial rigidity, allowing for precise axial vibration transmission, thereby improving machining capabilities and design flexibility in ultrasonic machining.
Implementation Method 1
an elastic clamping unit (13) disposed inside the rotor (12), wherein the elastic clamping unit (13) comprises a clamping element (131) for clamping the working tool (3) and a flexible hinge (133) contacting the clamping element (131)
Implementation Method 2
a vibrating unit (14) for providing the elastic clamping unit (13) with vibration against the rotor (12), wherein one end of the vibrating unit (14) is connected to an inner wall of the rotor (12) and the other end of the vibrating unit (14) is connected to the flexible hinge (133)
Data Source
AI summary
A spindle used in an ultrasonic machine for transmitting vibration to a working tool of the ultrasonic machine is disclosed. The spindle includes a main body, a rotor disposed in the main body, an elastic clamping unit disposed in the rotor, a vibrating unit having one end thereof connected to the inner wall of the rotor while the other end connected to the elastic clamping unit, and a pre-pressure unit penetrating the rotor and one end thereof connected to the elastic clamping unit to provide the elastic clamping unit with rigidity against the rotor, thereby making the elastic clamping unit provide pre-pressure to the vibrating unit which further provides the elastic clamping unit with vibration against the rotor. The present invention further provides a flexible hinge for the spindle.