Design of Longitudinal–Torsional Transducer and Directivity Analysis during Ultrasonic Vibration-Assisted Milling of Honeycomb Aramid Material

This paper presents a longitudinal–torsional transducer for use during the ultrasonic vibration-assisted milling (UVAM) of honeycomb aramid material. The mechanism of longitudinal–torsional conversion was analyzed to guide the design of a vibration transducer. The transducer features five spiral grooves around the front cover plate, which function under the excitation of a group of longitudinal piezoelectric ceramics. A portion of the longitudinal vibration was successfully converted into torsional vibration. The resonant frequency, longitudinal vibration displacement and torsional amplitude at the top of the disk milling cutter were 24,609 Hz, 19 μm and 9 μm, respectively. In addition, the directivity of the longitudinal–torsional transducer was theoretically analyzed. Compared with conventional milling, UVAM with the longitudinal-torsional could significantly reduce the cutting force (40–50%) and improve the machining stability.