presentation 8h levesque
TRANSCRIPT
-
7/24/2019 Presentation 8h Levesque
1/26
Ultrasonic Machining for
Nuclear Fabrication and PWSCCMitigation
Matt Short - EWI
Technology Leader
ATI CSC11
Paper 8H 09/29/2011
Steve Levesque
Project Manager
-
7/24/2019 Presentation 8h Levesque
2/26
High Frequency Ultrasonics
! High-frequency ultrasonics convey information
-
7/24/2019 Presentation 8h Levesque
3/26
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 ~
-
7/24/2019 Presentation 8h Levesque
4/26
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
-
7/24/2019 Presentation 8h Levesque
5/26
Prior Work
Cincinnati Milacron US
turning, 1960s
Grumman US Drilling,
1970s
OSU, US Cutting
1970s
Sonobond Drilling,
Turning 1970s
-
7/24/2019 Presentation 8h Levesque
6/26
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
-
7/24/2019 Presentation 8h Levesque
7/26
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
1/2
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%
-
7/24/2019 Presentation 8h Levesque
8/26
Progression of Ultrasonic Machining
Lath Test Bed EWI Drill #1
-
7/24/2019 Presentation 8h Levesque
9/26
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
-
7/24/2019 Presentation 8h Levesque
10/26
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
-
7/24/2019 Presentation 8h Levesque
11/26
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
-
7/24/2019 Presentation 8h Levesque
12/26
Extending Technology to NuclearApplications
! Is it possible to integrate an US transmission line toportable equipment such as AREVAs drillinghardware
-
7/24/2019 Presentation 8h Levesque
13/26
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
-
7/24/2019 Presentation 8h Levesque
14/26
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
-
7/24/2019 Presentation 8h Levesque
15/26
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
-
7/24/2019 Presentation 8h Levesque
16/26
The Transmission Line
! Design each component as half or full wavelength, thencombine components into a multi-wave assembly
$ $/2 $/2
-
7/24/2019 Presentation 8h Levesque
17/26
AREVA Design Concept
! Successfully isolated all vibrations from surroundingequipment
! Continues to drive longitudinal vibrations
-
7/24/2019 Presentation 8h Levesque
18/26
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
-
7/24/2019 Presentation 8h Levesque
19/26
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
-
7/24/2019 Presentation 8h Levesque
20/26
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
-
7/24/2019 Presentation 8h Levesque
21/26
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
-
7/24/2019 Presentation 8h Levesque
22/26
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
-
7/24/2019 Presentation 8h Levesque
23/26
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
-
7/24/2019 Presentation 8h Levesque
24/26
Results
-
7/24/2019 Presentation 8h Levesque
25/26
For technical questions or to requestmore information, contact:
Gary R. Poling, P.E.
Special Projects
AREVA NP, Inc. - CR&R
434.832.2962
Matt Short
Technology Leader Ultrasonics
EWI
614.688.5137
-
7/24/2019 Presentation 8h Levesque
26/26