Fabrication of Conformal Ultrasound Transducer Arrays and Horns Based on Multi-Axis CNC Accumulation

2011 ◽  
Author(s):  
Yayue Pan ◽  
Chi Zhou ◽  
Yong Chen ◽  
Jouni P. Partanen
Keyword(s):  
Tool Path ◽  
Ultrasound Transducer ◽  
Prototype System ◽  
Test Cases ◽  
Internal Organs ◽  
Acoustic Performance ◽  
Spherical Surfaces ◽  
Transducer Arrays ◽  
Planning Methods ◽  
Potential Use

Ultrasonic imaging is an important medical imaging technique. It uses ultrasound over 20K Hz to detect and visualize muscles, tendons, and many internal organs. Previous studies have shown that an improved acoustic performance can be achieved by conformal ultrasound transducer arrays and horns that can wrap conformably around curved surfaces. To address challenges in fabricating such curved ultrasound transducer arrays and horns, we investigate the possibility of using a newly developed additive manufacturing (AM) process named CNC accumulation. In such an AM process, an accumulation tool can have multi-axis motion, which is beneficial for building conformal ultrasound transducer arrays and horns on a curved surface. To address different resolution requirements, we illustrate the use of multiple accumulation tools that can have different curing sizes and power in the fabrication of a single component. The tool path planning methods for any given cylindrical and spherical surfaces have been discussed. Based on the developed prototype system, various test cases have been performed. The experimental results have illustrated the capability of the process and its potential use in the fabrication of conformal ultrasound transducer arrays and horns. The current limitations and future development have also been discussed.

Multitool and Multi-Axis Computer Numerically Controlled Accumulation for Fabricating Conformal Features on Curved Surfaces

2014 ◽  
Vol 136 (3) ◽  
Author(s):  
Yayue Pan ◽  
Chi Zhou ◽  
Yong Chen ◽  
Jouni Partanen
Keyword(s):  
Tool Path ◽  
Prototype System ◽  
Test Cases ◽  
Curved Surfaces ◽  
Engineering Systems ◽  
Multiple Test ◽  
Optical Cable ◽  
Spherical Surfaces ◽  
Computer Numerically Controlled ◽  
Planning Methods

In engineering systems, features such as textures or patterns on curved surfaces are common. In addition, such features, in many cases, are required to have shapes that are conformal to the underlying surfaces. To address the fabrication challenge in building such conformal features on curved surfaces, a newly developed additive manufacturing (AM) process named computer numerically controlled (CNC) accumulation is investigated by integrating multiple tools and multiple axis motions. Based on a fiber optical cable and a light source, a CNC accumulation tool can have multi-axis motion, which is beneficial in building conformal features on curved surfaces. To address high resolution requirement, the use of multiple accumulation tools with different curing sizes, powers, and shapes is explored. The tool path planning methods for given cylindrical and spherical surfaces are discussed. Multiple test cases have been performed based on a developed prototype system. The experimental results illustrate the capability of the newly developed AM process and its potential use in fabricating conformal features on given curved surfaces.

Ultrasound Transducer Array Fabrication Based on Additive Manufacturing of Piezocomposites

2012 ◽  
Author(s):  
Hamid Chabok ◽  
Chi Zhou ◽  
Yong Chen ◽  
Arash Eskandarinazhad ◽  
Qifa Zhou ◽  
...  
Keyword(s):  
Additive Manufacturing ◽  
Ultrasound Transducer ◽  
Prototype System ◽  
Sintering Process ◽  
Projection System ◽  
Complex Shapes ◽  
Transducer Arrays ◽  
Ceramic Components ◽  
Digital Micromirror Devices ◽  
Future Work

Conventional methods for fabricating ultrasound imaging transducer arrays, especially for high frequency range (>20 MHz), are expensive, time consuming and limited to relatively simple geometries. In this paper, the development of an additive manufacturing (AM) process based on digital micromirror devices (DMDs) is presented for the fabrication of piezoelectric devices such as ultrasound transducer arrays. Both green-part fabrication and the sintering of fabricated green-parts have been studied. A novel two-channel design in the bottom-up projection system is presented to address the piezo-composite fabrication challenges including a small curing depth and viscous ceramic slurry recoating. A prototype system has been developed for the fabrication of green-parts with complex shapes and small features. Based on the fabricated green-parts, the challenges in the sintering process for achieving desired functionality are discussed. Various approaches for increasing the density of sintered components are presented. Dielectric and piezoelectric properties of the fabricated samples are measured and compared with those of bulk PZT samples. Based on the identified challenges in the DMD-based AM process, future work for achieving fully functional piezoelectric ceramic components is discussed.

Study of The Tool Path Generation Method of an Ultra-Precision Spherical Complex Surface Based on a Five-Axis Machine Tool

2021 ◽  
Author(s):  
Tianji Xing ◽  
Xuesen Zhao ◽  
Zhipeng Cui ◽  
Rongkai Tan ◽  
Tao Sun
Keyword(s):  
Surface Roughness ◽  
Tool Path ◽  
Spherical Surface ◽  
Tool Path Generation ◽  
Path Generation ◽  
Tool Paths ◽  
Spherical Surfaces ◽  
Spherical Complex ◽  
Ultra Precision ◽  
Five Axis

Abstract The improvement of ultra-precision machining technology has significantly boosted the demand for the surface quality and surface accuracy of the workpieces to be machined. However, the geometric shapes of workpiece surfaces cannot be adequately manufactured with simple plane, cylindrical, or spherical surfaces because of their different applications in various fields. In this research, a method was proposed to generate tool paths for the machining of complex spherical surfaces based on an ultra-precise five-axis turning and milling machine with a C-Y-Z-X-B structure. Through the proposed tool path generation method, ultra-precise complex spherical surface machining was achieved. First, the complex spherical surface model was modeled and calculated, and then it was combined with the designed model to generate the tool path. Then the tool paths were generated with a numerically controlled (NC) program. Based on an ultra-precision three-coordinate measuring instrument and a white light interferometer, the machining accuracy of a workpiece surface was characterized, and t[1]he effectiveness of the provided tool path generation method was verified. The surface roughness of the machined workpiece was less than 90 nm. Furthermore, the surface roughness within the spherical region appeared to be less than 30 nm. The presented tool path generation method in this research produced ultra-precision spherical complex surfaces. The method could be applied to complex spherical surfaces with other characteristics.

Low-cost monolithic processing of large-area ultrasound transducer arrays

2019 ◽  
Author(s):  
L. C. J. M. Peters ◽  
R. Ollearo ◽  
R. G. F. A. Verbeek ◽  
J. L. P. J. van der Steen ◽  
H. B. Akkerman ◽  
...  
Keyword(s):  
Low Cost ◽  
Ultrasound Transducer ◽  
Large Area ◽  
Transducer Arrays

Efficient NC Tool Path Planning Based on the Subdivision of Sculptured Surface

2014 ◽  
Vol 635-637 ◽  
pp. 497-501
Author(s):  
Li Min ◽  
Biao Bai ◽  
Yu Hou Wu ◽  
De Hong Zhao
Keyword(s):  
Path Planning ◽  
Tool Path ◽  
High Efficiency ◽  
Parametric Method ◽  
Sculptured Surface ◽  
Machining Efficiency ◽  
Tool Path Planning ◽  
Tool Paths ◽  
Surface Subdivision ◽  
Planning Methods

In this paper, we have presented a method to generate efficient NC tool paths based on the surface subdivision. The main objective is to achieve high efficiency in the machining of sculptured surface. The NC machining efficiency can be improved by segmenting the whole surface into distinct areas according to the characters of sculptured surface and by using different size mills and different tool path planning methods to machine the areas. The iso-parametric method and large mills are used in the curvature changing little areas. While the iso-scallop method and small mills are used in curvatures changing large areas. This can make full use of tool path generation methods and mills, which improve the machining efficiency of sculpture effectively.

Computing Cutter Engagement Values in Milling Tessellated Free-Form Surfaces

2010 ◽  
Vol 10 (4) ◽  
Author(s):  
Zhiyang Yao ◽  
Ajay Joneja
Keyword(s):  
Computational Model ◽  
Cutting Force ◽  
High Speed ◽  
Tool Path ◽  
Free Form ◽  
High Speed Milling ◽  
Free Form Surfaces ◽  
Potential Use ◽  
Do So

High speed milling (HSM) has great potential use in die/mold cutting, but traditional machining plans do exploit HSM capabilities effectively. An important consideration in HSM is to limit cutting force variations, and one way to do so is to reduce cutter-workpiece engagement (CWE) variations. CWE is measured as the area of the tool instantaneously engaged with the part. Estimating CWE as a function of the tool path requires repeated, expensive computations. This paper develops algorithms for a discretized computational model to make CWE computations for arbitrary shaped parts.

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