Solving Joint Surface Stress: A New Ultrasonic Method

Machine tools, like any complex system, have a weak link—the joint surface. This surface plays a crucial role in determining the machine's overall stiffness and accuracy during machining. Understanding the distribution of contact stress here is vital but tricky. Scientists have now come up with a clever way to tackle this issue using ultrasonic testing. They've proposed a method that relies on the equivalent medium theory to measure tangential contact stress. This method involves creating a virtual material model of the rough contact interface using fractal theory. They've also derived expressions for how ultrasonic critical refracted longitudinal waves behave under stress.To put this into practice, they've designed experiments where specimens are subjected to stress, and this stress is measured based on how the surface is divided into grids. The stress in the X and Y directions is used to calculate the equivalent stress value for each node. They've even drawn a fancy cloud map to show the distribution of shear stress on the contact surface. The accuracy of this method has been confirmed through a combination of theory, simulation, and experimental techniques. This ultrasonic method is particularly useful for low-stress assemblies.