Variable-Curvature Ultrasonic Blade for 3D Curved Surface Cutting

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Solution Overview

Problem

Conventional cutting techniques face challenges in shaping three-dimensional curved surfaces, particularly in manufacturing operations where precise cutting or trimming is required, as they struggle to effectively manage varying radii of curvature and reduce chatter during ultrasonic cutting operations.

Innovation Solution

The development of an ultrasonic cutting blade with a curved body featuring a varying radius of curvature between a minimum and maximum radius, along with an ultrasonic cutting system that transmits vibrations through dual contact interfaces to reduce chatter, allowing for adaptive cutting angles and paths to form complex, arcuate cuts with controlled radii.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If conventional cutting techniques are used to shape three-dimensional curved surfaces, then the cutting process is simple, but the ability to effectively manage varying radii of curvature and reduce chatter is poor

Engineering Contradiction:

Improvecutting precision on curved surfacesVSAvoidblade structure complexity

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The blade is designed with a curved body where the radius of curvature varies along its length, allowing different sections to adapt to varying radii of curvature on the workpiece surface. This dynamic geometric adaptation enables precise cutting on complex three-dimensional curved surfaces while maintaining a relatively simple overall blade structure

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The blade's radius of curvature parameter is varied along its length to match the varying radii of curvature on the workpiece. By changing this geometric parameter spatially, the blade can effectively cut different sections of curved surfaces with different curvature requirements, improving manufacturing precision without requiring multiple blades

Inventive Principle:

Principle #35Parameter changes

2Reliability

If ultrasonic vibrations are transmitted through a single contact interface, then the blade holder structure is simple, but chatter during cutting operations increases

Engineering Contradiction:

Improvecutting stabilityVSAvoidblade holder structure complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The ultrasonic vibration transmission is segmented into two separate contact interfaces between the blade and blade holder. This segmentation allows each interface to be optimized for specific functions: one interface primarily transmits ultrasonic vibrations while the other provides mechanical support and positioning. The separation of functions reduces chatter by preventing the coupling of vibration transmission and mechanical constraint, improving cutting stability

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The blade holder acts as an intermediary element that connects the ultrasonic vibration source to the cutting blade through two distinct contact interfaces. This intermediary structure mediates between the vibration source and the blade, allowing optimized transmission of ultrasonic vibrations while maintaining proper mechanical alignment and reducing chatter during cutting operations

Inventive Principle:

Principle #24Intermediary (Mediator)

3Adaptability or versatility

If a straight blade is used for cutting, then the blade design is simple, but the ability to form complex contours and adapt to varying radii is limited

Engineering Contradiction:

Improveadaptability to varying radii of curvatureVSAvoidblade geometry complexity

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The blade is designed with a curved body instead of a straight geometry. The curved shape, with its varying radius of curvature, allows the blade to naturally conform to and cut three-dimensional curved surfaces and complex contours. This curvature-based design provides adaptability to varying radii of curvature on workpieces while maintaining a relatively simple continuous blade structure

Inventive Principle:

Principle #14Spheroidality (Curvature)

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 precise cutting of three-dimensional curved surfaces with reduced chatter, improving cut quality and extending blade life by optimizing vibration transmission and adapting to changing cutting angles and radii, facilitating the creation of complex contours in a single pass.

Implementation Method 1

an ultrasonic cutting tool that transmits ultrasonic vibrations to the ultrasonic cutting blade

Methodology Applied

Scientific EffectUltrasonic vibration: Ultrasonic Vibration

Implementation Method 2

transferring ultrasonic vibrations through two contact interfaces between an ultrasonic cutting blade and a blade holder

Methodology Applied

Scientific EffectVibration transmission: Vibration

Data Source

PatentUS20240326276A1Ultrasonic cutting blades and systems and methods for cutting workpieces

Publication Date: 2024.10.03 THE BOEING CO

AI summary

An ultrasonic cutting blade includes a first end, a second end, and a curved body. The curved body extends between the first end and the second end. The curved body includes a first edge that is configured to contact a workpiece for performing a cutting operation on the workpiece. The curved body includes a radius of curvature that varies between a minimum radius of curvature and a maximum radius of curvature.