Citation: Li, P.; Chen, Y.; Li, W.; Sun,
J.; Li, J.; Wang, K. Design of
Longitudinal-Bending Coupled Horn
of a Giant Magnetostriction
Transducer. Actuators 2022, 11, 110.
https://doi.org/10.3390/
act11040110
Academic Editor: Doron Shilo
Received: 16 March 2022
Accepted: 14 April 2022
Published: 16 April 2022
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Article
Design of Longitudinal-Bending Coupled Horn of a Giant
Magnetostriction Transducer
Pengyang Li
1,
* , Yunshuai Chen, Wei Li, Jian Sun, Jian Li and Kai Wang
School of Mechanical and Precision Instrument Engineering, Xi’an University of Technology, Xi’an 710048, China;
1200211009@stu.xaut.edu.cn (Y.C.); li2507877981@163.com (W.L.); 1210211011@stu.xaut.edu.cn (J.S.);
2200220076@stu.xaut.edu.cn (J.L.); 2200221202@stu.xaut.edu.cn (K.W.)
* Correspondence: lipengyang@xaut.edu.cn
Abstract:
This article presents a design method of Longitudinal-Bending Coupled Horn (L-BCH)
of a giant magnetostrictive transducer utilized in spinning ultrasonic machining. The structural
parameters are initially determined by the design theory of the horn and thick disc. Then, the effect
of the structural parameters of the rotating wheel on the vibration characteristics of the L-BCH are
explored by the model and harmonic response analysis through the finite element method. Through
continuous modification of the geometrical parameters of the rotary wheel, the L-BCH meeting the
requirements of a giant magnetostrictive transducer is designed. Finally, the frequency and amplitude
measurements are performed on the prototype by the impedance analyzer and the laser vibrometer.
The finite element analysis and experimental results show that: the large diameter, small diameter,
thickness, and fillet radius of the rotating wheel have different impacts on the dynamic characteristics
of the L-BCH. Among them, the thickness of the rotary wheel has the most significant influence on
the natural frequency and amplitude. In addition, the rotating wheel has a pitch circle when the
longitudinal-bending coupled vibration occurs, and the structure itself also has the characteristic of
amplifying amplitude.
Keywords: longitudinal-bending coupled horn; structural design; kinetics analysis
1. Introduction
Typical rotating parts with a sizeable diameter-thickness ratio, ultra-thin wall, high-
performance features (e.g., new warplane nozzle, spacecraft cowl) can be manufactured
by vigorous spinning, which has the advantages of the complete structure, high precision,
good comprehensive performance, high material utilization and so on [
1
–
4
]. In machining,
the ultra-thin wall tube is prone to defects, such as expanding, bulging and warping due
to its thin wall thickness, sizeable diameter-to-thickness ratio, and poor rigidity. Mean-
while, the surface of the ultra-thin wall tube is easy to be torn because of the accumulation
of circumferential distortion during multi-pass spinning [
5
]. In nuclear technology, the
central pump shield made by a new type of nuclear power nickel-based alloy has a con-
siderable spinning pressure due to its large yield limit in cold power spinning. However,
there is a new contradiction between the enormous spinning pressure and the demand
for high-quality products [
6
]; As spinning pressure increases, product defects and scrap
rates increase. The introduction of ultrasonic vibration in solid spinning processing can
effectively reduce the forming force and friction, improving the surface accuracy of parts.
The surface quality of parts resulting from excessive spinning pressure can be solved [
7
,
8
].
In spinning, ultrasonic energy is transferred to the rotary wheel through the horn and then
acts on the workpiece to realize ultrasonic spinning. The longitudinal-vibrating horn and
the bending-vibrating wheel form L-BCH. However, the horn vibrates longitudinally, the
wheel vibrates flexural, and the geometric size of the bending vibration disk significantly
influences the system’s resonant frequency [
9
]. Therefore, to maximize the effectiveness of
Actuators 2022, 11, 110. https://doi.org/10.3390/act11040110 https://www.mdpi.com/journal/actuators
