Desktop microforming and welding system powered by a flextensional Terfenol-D transducer

TL;DRAbstract

Magnetostrictive Terfenol-D was examined as a prime-mover for bulk motion in a microforming system. Careful design and analysis led to the creation of a Terfenol-D transducer capable of 3.8 kN of blocked force and 212 μm of displacement. A linear model of the Terfenol-D transducer to simulate its output as a function of displacement under saturation magnetic field was created that matched both force and displacement within 10%. Thermal drift occurred at a rate of 2 μm/oC. A flextensional lever system was designed to amplify the displacement of the Terfenol-D transducer to levels sufficient for microforming. Sub-micron displacement resolution was observed, with no perceivable effects from friction or backlash. The full system provided 365 N of blocked force and 1.6 mm of displacement. A linear model of the full system was also created that used the linear model of the transducer’s output which matched experimental results for displacement with a 2% error and force with an 11% error, whi

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