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Proceedings Paper

Bulk motion for ultrasonic-assisted microforming using Terfenol-D
Author(s): Adam T. Witthauer; LeAnn E. Faidley; Gap-Yong Kim
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Paper Abstract

Microforming requires high-precision motion due to scaling issues. A Terfenol-D transducer was considered to provide bulk motion for micro-extrusion. Because Terfenol-D cannot practically produce the necessary 2.5 mm displacement for this micro-extrusion experiment, a lever system was designed to amplify the output displacement. Compliant joints (flexures) were used to replace conventional bearings, resulting in a flexible, solid-state lever mechanism. By eliminating the backlash and static friction associated with conventional bearings, it should be possible to improve displacement precision as required to meet the geometric tolerance demands of microforming. A chief concern when designing flexure joints that see large amounts of axial loading is compliance, which leads to not only loss of motion but also loss of accuracy as the lever system responds differently under different loads. However, because Terfenol-D already has load-dependent response, this loss of accuracy is moot when coupled with a Terfenol-D prime mover, as it already requires load-dependent control. Preliminary FEM analysis has shown this design to have lever ratio losses of approximately 4% from half load to full load, with lower than predicted stress.

Paper Details

Date Published: 29 March 2010
PDF: 10 pages
Proc. SPIE 7645, Industrial and Commercial Applications of Smart Structures Technologies 2010, 76450N (29 March 2010); doi: 10.1117/12.848287
Show Author Affiliations
Adam T. Witthauer, Iowa State Univ. (United States)
LeAnn E. Faidley, Iowa State Univ. (United States)
Gap-Yong Kim, Iowa State Univ. (United States)

Published in SPIE Proceedings Vol. 7645:
Industrial and Commercial Applications of Smart Structures Technologies 2010
M. Brett McMickell; Kevin M. Farinholt, Editor(s)

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