A novel method for effecting flexible guided wave propagation in elliptical vibration cutting.

As a key part of elliptical vibration cutting (EVC) technology, a two-dimensional ultrasonic elliptical vibration cutting (UEVC) device has become a prevalent area of importance and research interest. This paper dissects through the conventional structural design and creatively proposes the UEVC device with flexible guided wave propagation. The device resolves the problems of poor coupling efficiency of two-way excitation signal, complex structure design, non-orthogonal, and the difficulty in controlling the ellipse trajectories of the tool tip. It has been confirmed that a flexible guided wave exhibits an effective unidirectional propagation and lateral load decoupling ability via establishing its system dynamic response and frequency impedance characteristics. Here, we explain the coupling mechanism of the two-way flexible guided wave in the UEVC device. Results suggested that the experimental measurement of the impedance for the cutting device and the individual transducer shows that the cutting device with the transducer and the tool bar connected by the flexible guided wave has a lower impedance increase ratio compared to the individual transducer, and hardly influence the tool bar mode of the cutting device. At the same time, the tool tip trajectory of the cutting device having a phase difference of 90° showed a satisfactory "elliptical" shape, while the microstructure processed by the tool tip ellipse trajectory with a phase difference of 60° reached a burr-free state. Theoretical and experimental findings reveal that the flexible guided waves exhibit excellent weak coupling characteristics in the non-transmitting direction. This is convenient to the independent, orthogonal and stable propagation of signals in the two directions. Based on flexible guided wave propagation technology, our findings provide theoretical foundation and application value for the design of a two-dimensional UEVC device. • Proposed an innovative method to realize ultrasonic elliptical vibration cutting driven by two-way flexible guided wave. • The frequency impedance model of flexible guided wave ultrasonic elliptical vibration cutting device is established. • The two excitation signals independently drive the tool bar, and the device design becomes simple. • The ultra-precision burr-free machining of microstructures is completed by using the controllable ellipse trajectory. [ABSTRACT FROM AUTHOR]