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Title: Design and modelling of a miniaturised ultrasonic machining system
Author: Boongsood, Wanwanut
Awarding Body: University of Liverpool
Current Institution: University of Liverpool
Date of Award: 2012
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Ultrasonic Machining (USM) is the outstanding manufacturing process for producing complex cavities for all materials subjected to brittle fracture without the requirements of electrical/thermal conductivity or chemical reactivity. As a result, a wide range of materials can be fabricated efficiently. Even though the process benefits a variety of applications, the use of this method is not widespread because of the complexity of a large number of interacting parameters affecting the machining operation. Additionally, commercial machines available in the market tend to be rather large. In an age of micro. manufacturing and nanotechnology, as well as sustainable development, it is wasteful to machine hard and brittle materials in meso/micro scale geometries with the large equipment currently available. This research developed a miniaturised USM system. The effects of each of the different design parameters were considered and organised effectively using the Axiomatic Design approach to understanding the behaviour of a complex system. The system components were designed, modelled and then simulated with Finite Element Analysis software to characterise their responses, and were also optimised using a Design and Experiments method for a robust design. Prototypes were built and tested to validate the design. The dynamic characteristics based on prototype testing did not agree well with the computer simulation results. It was believed that this was the result of non-linearity behaviour caused by electrical impedance mismatching. Glass ceramic machining was investigated. A prediction equation of machining rates was proposed in a simple form. Through the novel miniature design, the material removal rates were comparatively superior compared with conventional systems while the size of the proposed transducer and horn assembly was reduced to half that of typical horn shapes.
Supervisor: Not available Sponsor: Not available
Qualification Name: Thesis (Ph.D.) Qualification Level: Doctoral
EThOS ID:  DOI: Not available