Presentation 8h Levesque

7/24/2019 Presentation 8h Levesque

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Ultrasonic Machining for

Nuclear Fabrication and PWSCCMitigation

Matt Short - EWI

Technology Leader

[email protected]

ATI CSC11

Paper 8H 09/29/2011

Steve Levesque

Project Manager

[email protected]


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High Frequency Ultrasonics

! High-frequency ultrasonics convey information


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High-Power Ultrasonics (HPU)

! HPU - application of intense, high-frequencyacoustic energy to changematerials,processes

Ultrasonic energycauses change inMaterial or Process

UltrasonicTransducer

Transmission

Material/Process

Power supply

60 ~


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Ultrasonic MachiningTechnical Background

! What is Ultrasonic Machining (UM)! It is application of ultrasonic (US) vibrations to traditional

machining processes (drilling, turning, milling ") to improveperformance (e.g., faster drilling, drilling of hard materials, bettertool life, increased accuracy, ")

Concepts of adding USvibrations to

various machining

processes


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Prior Work

Cincinnati Milacron US

turning, 1960s

Grumman US Drilling,

1970s

OSU, US Cutting

1970s

Sonobond Drilling,

Turning 1970s


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Progression of Ultrasonic Machining

! EWI approach to US Machining

! Utilization of higher US power than previously used (starting at 4.5 kW)

! Take advantage of better control technology of modern US systems

! Apply modern FEA analysis to tool development

! Initial Application

! Jointly sponsored NASA, NCDMM program on US Twist Drilling

4.5- vs. 2.5-kWTransducer

Dukane 5-kW GeneratorsVibrational Analysis

of Twist Drill


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NCDMM Testing

! Focused on 6061-T6; 1/8

and ! drills

! Used dynamometer to evaluate drilling forces, torques

! Showed significant reductions in normal force and torque when drillingaluminum

! Optimum vibration amplitude

! For 4340 steel, system torque and rpm insufficient for tools >1/2-in

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Drill in 6061 Al

Amplitude Mz Fz Mz Reduction Fz Reduction

0 27.74 1263.3

37 12.41 389.9 55.26% 69.14%

45 9.195 431.1 66.85% 65.88%

55 16.67 763.1 39.91% 39.59%


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Progression of Ultrasonic Machining

Lath Test Bed EWI Drill #1


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Drilling Tests

! ! drill bit into " steel plate! without sonics: 45s! with sonics: 15s

! Power draw up to 2kW

! 1/8

drill bit into #

steel plate! without sonics: 15s

! with sonics: 1.2s! Power draw up to 600W

! " drill in development

holes in

steel plate


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Tool Life Assessment

! Tool Performance With and W/O US! Trials conducted on Inconel, no lubricant

! Cutting edge wear indicated W/O US

! Third pass showed significant wear

Wearindicated

Severe wear

Hole 1 Hole 2 Hole 3

Materialtransfer

No USEnergy

With USEnergy


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Tool Life Assessment

! Loads increase as wear increases

Hole 1 W/out US

~40-N

~70-N

Hole 2 W/out US

~65-N

~85-N

Hole 3 W/out US

~90-N~150-N

Hole 1 with US

~55-N ~65-N

Hole 2 with US

~55-N~65-N

Hole 3 with US

~70-N ~70-N


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Extending Technology to NuclearApplications

! Is it possible to integrate an US transmission line toportable equipment such as AREVAs drillinghardware


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Challenges

! Climax Drill Design!

Improve overall process efficiency

! Process speed

! Tool wear

!

Surface finish! Dimensional stability

! Clearance of transducer on platform

! Stack-up length

! Ease of use and adaptability

!

Use of internal mandrel acting as collet!Ability to revert to standard practice

with minimal effort


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Transducer Overview

! Off-the-shelf transducer designed to operate at 20-kHz

! If the components are not tuned properly, it will notwork

Transducer end

28-32 #m


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20242 Hz

! Shank modified by reducing length of Morse taper tooverall length of 10.87! This does not take into account shrink fit portion of shank due to

tuning

Finite Element Analysis


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The Transmission Line

! Design each component as half or full wavelength, thencombine components into a multi-wave assembly

$ $/2 $/2


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AREVA Design Concept

! Successfully isolated all vibrations from surroundingequipment

! Continues to drive longitudinal vibrations


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AREVA System Overview

! Transmission Line Components! Rigid, interchangeable shrink-fit collet

! Half wave extension

! Transducer

! Assembly!

Each component makes up $/2

!

Accomplished with single bolt at interface

Transducer

Mandrel/Shrink-FitCollet

Half WaveExtension

PatentPending


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AREVA System Overview

! Climax Drill Assembly! Install Collet/Mandrel into drill bore engaging drive key

! Transmission lines transmits torque while transmitting acousticalvibrations to cutting faces

! Protective boot covers $/2 extension and provides easy removal

!

Transducer attaches to back side of extension


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AREVA Drilling Results

! Capable of performing operationin 36-sec. Not desirable due tosurface finish

! Successfully met surfacerequirements at ~5-min operationtime

! Improved true position of hole

! Maintained ability to revert toMorse taper tooling

!

Completely isolated vibrationsfrom drill head

! Capable of performing severaloperations with same drill bit


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Ongoing Developments

! Development of a machining center compatible US machiningunits (e.g. drilling tools and/or milling tools) will be a next step inexpanding US machining technology

Haas 5-axis MC


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Design Details

! Concept to incorporate 20-kHztransducer into live spindlecase! Must consider the following:

!

Electrical contacts! Various mounting provisions acceptingdifferent size tool holders

! HSK/CAT 40, 60, etc.

! Repairable/serviceable

! Use of shrink-fit tooling

!

Isolate vibrations from spindle


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Vibration Analysis

0

2

4

6

8

10

12

14

16

18

0

35.00% 45.00% 55.00% 65.00% 75.00% 85.00% 95.00% 105.00%

Long. Node Amp Displacement Radial Amp at Nodal Position

Bore Face Amp Displacement Tool Tip Displacement

Back Mass Long. Amp Displacement Radial Amp at Back MassLong. Amp. @ Tool Holder Interface Rad. Amp. @ Back End of Case

Rad. Amp. @ Node Position with Case


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Results


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For technical questions or to requestmore information, contact:

Gary R. Poling, P.E.

Special Projects

AREVA NP, Inc. - CR&R

434.832.2962

[email protected]

Matt Short

Technology Leader Ultrasonics

EWI

614.688.5137

[email protected]


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Presentation 8h Levesque

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