Ultrasonic Machining for

Nuclear Fabrication and PWSCC

Mitigation
Matt Short - EWI
Technology Leader
614.688.5137
mshort@ewi.org

ATI CSC11
Paper 8H 09/29/2011

Steve Levesque
Project Manager
614.688.5183
slevesque@ewi.org

High Frequency Ultrasonics

u

High-frequency ultrasonics convey information

High-Power Ultrasonics (HPU)

u HPU - application of intense, high-frequency

acoustic energy to change materials,

processes

Power supply
Ultrasonic
Transducer
60 ~

Ultrasonic energy
causes change in
Material or Process

Transmission

Material/Process

Ultrasonic Machining
Technical Background
!!

What is Ultrasonic Machining (UM)

!! It is application of ultrasonic (US) vibrations to traditional
machining processes (drilling, turning, milling ") to improve
performance (e.g., faster drilling, drilling of hard materials, better
tool life, increased accuracy, ")

Concepts of adding US
vibrations
to
various machining
processes

Prior Work

Cincinnati Milacron US
turning, 1960
s

Grumman US Drilling,
1970
s

OSU, US Cutting
1970
s
Sonobond Drilling,
Turning 1970
s

Progression of Ultrasonic Machining

u

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-kW
Transducer

Dukane 5-kW Generators

Vibrational Analysis
of Twist Drill

NCDMM Testing
u
u

Focused on 6061-T6; 1/8 and drills

Used dynamometer to evaluate drilling forces, torques
Showed significant reductions in normal force and torque when drilling
aluminum
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
37
45
55

27.74
12.41
9.195
16.67

1263.3
389.9
431.1
763.1

55.26%
66.85%
39.91%

69.14%
65.88%
39.59%

Progression of Ultrasonic Machining

Lath Test Bed

EWI Drill #1

Drilling Tests
u

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

Tool Life Assessment

u

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
Wear
indicated

Severe wear

No US
Energy

Material
transfer

With US
Energy
Hole 1

Hole 2

Hole 3

Tool Life Assessment

u

Loads increase as wear increases

Hole 1 W/out US

~70-N
~40-N

~85-N

~65-N

~150-N
~90-N

Hole 1 with US

~55-N

Hole 3 W/out US

Hole 2 W/out US

~65-N

Hole 2 with US

~55-N

~65-N

Hole 3 with US

~70-N

~70-N

Extending Technology to Nuclear

Applications
u

Is it possible to integrate an US transmission line to

portable equipment such as AREVA s drilling
hardware

Challenges
u

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

Transducer Overview
u
u

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

If the components are not tuned properly, it will not
work

Transducer end

28-32 m

Finite Element Analysis

u

Shank modified by reducing length of Morse taper to

overall length of 10.87
This does not take into account shrink fit portion of shank due to
tuning

20242 Hz

The Transmission Line

u

Design each component as half or full wavelength, then

combine components into a multi-wave assembly

/2

/2

AREVA Design Concept

!!
!!

Successfully isolated all vibrations from surrounding

equipment
Continues to drive longitudinal vibrations

AREVA System Overview

u

Transmission Line Components

Rigid, interchangeable shrink-fit collet
Half wave extension
Transducer

Assembly
Each component makes up /2
Accomplished with single bolt at interface
Mandrel/Shrink-Fit
Collet

Patent
Pending

Half Wave
Extension

Transducer

AREVA System Overview

u

Climax Drill Assembly

Install Collet/Mandrel into drill bore engaging drive key
Transmission lines transmits torque while transmitting acoustical
vibrations to cutting faces
Protective boot covers /2 extension and provides easy removal
Transducer attaches to back side of extension

AREVA Drilling Results

u

u
u
u
u

Capable of performing operation

in 36-sec. Not desirable due to
surface finish
Successfully met surface
requirements at ~5-min operation
time
Improved true position of hole
Maintained ability to revert to
Morse taper tooling
Completely isolated vibrations
from drill head
Capable of performing several
operations with same drill bit

Ongoing Developments
u

Development of a machining center compatible US machining

units (e.g. drilling tools and/or milling tools) will be a next step in
expanding US machining technology

Haas 5-axis MC

Design Details
u

Concept to incorporate 20-kHz

transducer into live spindle
case
Must consider the following:
Electrical contacts
Various mounting provisions accepting
different size tool holders
HSK/CAT 40, 60, etc.
Repairable/serviceable
Use of shrink-fit tooling
Isolate vibrations from spindle

Vibration Analysis

Static, Case Mounted

20
18
16
14
12
10
8
6
4
2
0
35.00%

45.00%

55.00%

65.00%

75.00%

85.00%

95.00%

Long. Node Amp Displacement

Radial Amp at Nodal Position

Bore Face Amp Displacement

Back Mass Long. Amp Displacement

Tool Tip Displacement

Radial Amp at Back Mass

Long. Amp. @ Tool Holder Interface

Rad. Amp. @ Node Position with Case

Rad. Amp. @ Back End of Case

105.00%

Results

For technical questions or to request

more information, contact:
Gary R. Poling, P.E.
Special Projects
AREVA NP, Inc. - CR&R
434.832.2962
Gary.Poling@areva.com

Matt Short
Technology Leader Ultrasonics
EWI
614.688.5137
mshort@ewi.org