Bulk motion for ultrasonic-assisted microforming using Terfenol-D

Adam T. Witthauer; LeAnn E. Faidley; Gap-Yong Kim

doi:10.1117/12.848287

29 March 2010 Bulk motion for ultrasonic-assisted microforming using Terfenol-D

Adam T. Witthauer, LeAnn E. Faidley, Gap-Yong Kim

Proceedings Volume 7645, Industrial and Commercial Applications of Smart Structures Technologies 2010; 76450N (2010) https://doi.org/10.1117/12.848287
Event: SPIE Smart Structures and Materials + Nondestructive Evaluation and Health Monitoring, 2010, San Diego, California, United States

Abstract

Microforming requires high-precision motion due to scaling issues. A Terfenol-D transducer was considered to provide bulk motion for micro-extrusion. Because Terfenol-D cannot practically produce the necessary 2.5 mm displacement for this micro-extrusion experiment, a lever system was designed to amplify the output displacement. Compliant joints (flexures) were used to replace conventional bearings, resulting in a flexible, solid-state lever mechanism. By eliminating the backlash and static friction associated with conventional bearings, it should be possible to improve displacement precision as required to meet the geometric tolerance demands of microforming. A chief concern when designing flexure joints that see large amounts of axial loading is compliance, which leads to not only loss of motion but also loss of accuracy as the lever system responds differently under different loads. However, because Terfenol-D already has load-dependent response, this loss of accuracy is moot when coupled with a Terfenol-D prime mover, as it already requires load-dependent control. Preliminary FEM analysis has shown this design to have lever ratio losses of approximately 4% from half load to full load, with lower than predicted stress.

Citation Download Citation

Adam T. Witthauer, LeAnn E. Faidley, and Gap-Yong Kim "Bulk motion for ultrasonic-assisted microforming using Terfenol-D", Proc. SPIE 7645, Industrial and Commercial Applications of Smart Structures Technologies 2010, 76450N (29 March 2010); https://doi.org/10.1117/12.848287

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