Simulation-Driven Design of Ultrasonic Horns for Precision Micro-Grinding Applications.

Madarkar, Rajeshkumar (2025) Simulation-Driven Design of Ultrasonic Horns for Precision Micro-Grinding Applications. In: Euspen’s Special Interest Conference on Micro/Nano Manufacturing & 6th AET Symposium on ACSM and Digital Manufacturing, 17th – 19th September 2025, Paris-Saclay University, France.

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Abstract

Abstract: High-precision micro-machining and grinding processes are increasingly vital for the fabrication of next-generation components in aerospace, biomedical, and semiconductor industries. As the demand for tighter tolerances, superior surface finish, and material integrity increases, conventional machining techniques face limitations in tool wear, heat generation, and material removal efficiency. Ultrasonic Vibration-Assisted Grinding (UVAG) and Ultrasonic Minimum Quantity Lubrication (UMQL) have emerged as promising solutions, enabling improved performance through high-frequency vibrations superimposed on conventional grinding operations. This research focuses on the simulation-based design and optimization of ultrasonic horns, critical components in delivering high-frequency energy, to enhance micro-grinding effectiveness. Traditional horn designs often rely on heuristic and trial-and-error methods, which are time-consuming and prone to detuning, especially in precision applications. To address this, we propose a comprehensive design framework integrating analytical modeling, finite element simulations, and experimental validation. Initial design begins with resonance length estimation using elastic wave propagation theory, followed by the development of parametric CAD models. Modal and harmonic analyses in ANSYS Workbench ensure tuning accuracy to the target frequency (20 kHz), maximize amplitude gain, and minimize stress concentrations. A coupled horn-workpiece model is simulated to replicate realistic operational conditions. Post-simulation, horns are fabricated using ultra-precision machining, and their vibrational characteristics are validated with frequency analysers and displacement measurement systems. Deviations from the simulated behavior are corrected via iterative refinement, ensuring system compatibility and robust performance. This study presents a robust and adaptable methodology for the design of ultrasonic horns specifically tailored to micro-machining and precision grinding applications. The approach significantly advances ultrasonic tool development by offering improved dimensional accuracy, streamlined design processes, and increased operational efficiency. Moreover, the methodology is well-aligned with Industry 4.0 principles, enabling seamless integration into digitally connected, data-driven manufacturing ecosystems.

Item Type:	Conference or Workshop Item (Paper)
Depositing User:	Research and Knowledge Exchange Office Admin 1
Date Deposited:	05 Feb 2026 11:12
Last Modified:	05 Feb 2026 11:12
URI:	https://bnu.repository.guildhe.ac.uk/id/eprint/20813

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