New systematic and time-saving procedure to design complex shaped tools for the application of ultrasonic assisted grinding

Ultrasonic grinding leads to a reduction of process forces while grinding brittle or hard materials. This effect on the other hand can be used to increase the material removal by increasing the in feed respectively. To assist good process conditions all components influencing the wave propagation have to be designed in a way that they have a longitudinal eigenfrequency at 20 kHz. To design those components very accurate a systematic and time saving procedure was generated that allows the selection of an optimized geometry out of a multitude of geometries after calculating their dynamic behavior. Therefore, the two software tools Ansys and Matlab were connected with each other to reduce the time-consuming steps while iteratively simulating the eigenparameters. The procedure was validated within multitude investigation at a piezo actor driven test set up.