Numerical study of cavitation shock wave emission in the thin liquid layer by power ultrasonic vibratory machining.

In the field of power ultrasonic vibration processing, the thin liquid layer nestled between the tool head and the material serves as a hotbed for cavitation shock wave emissions that significantly affect the material's surface. The precise manipulation of these emissions presents a formidable challenge, stemming from a historical deficit in the quantitative analysis of both the ultrasonic enhancement effect and the shock wave intensity within this niche environment. Our study addresses this gap by innovatively modifying the Gilmore-Akulichev equation, laying the groundwork for a sophisticated bubble dynamics model and a pioneering shock wave propagation model tailored to the thin liquid layer domain. Firstly, our study investigated the ultrasound enhancement effect under various parameters of thin liquid layers, revealing an amplification of ultrasound pressure in the thin liquid layer area by up to 7.47 times. The mathematical model was solved using the sixth-order Runge-Kutta method to examine shock wave velocity and pressure under different conditions. our study identified that geometric parameters of the tool head, thin liquid layer thickness, ultrasonic frequency, and initial bubble radius all significantly influenced shock wave emission. At an ultrasonic frequency of 60 kHz, the shock wave pressure at the measurement point exhibited a brief decrease from 182.6 to 179.5 MPa during an increase. Furthermore, rapid attenuation of the shock wave was found within the range of R-3R from the bubble wall. This research model aims to enhance power ultrasonic vibration processing technology, and provide theoretical support for applications in related fields.