The paper reports on a nonlinear frequency up-converting vibration energy harvester with enhanced broadband performance below 50 Hz, which is attained by leveraging vibro-impact interaction between two high-frequency piezoelectric generators and two low-frequency resonators with commensurate natural frequencies in the 2:1 ratio. Finite element model was implemented to assess the proposed concept by treating the harvester as a vibro-impact coupled piezoelectric-circuit system. The model accommodates multiple mechanical contact pairs defined by nonlinear dissipative Hunt–Crossley contact force formulation. Effective design principles were applied to maximize power output including near-optimal positioning of the neutral plane in the generators and rational adjustment of response settling time. The fabricated proof-of-concept device was tested in different clearance configurations and under varying harmonic excitation conditions to reveal rich nonlinear dynamics behavior. The measured hardening-type power frequency responses were examined to gain better insight into nonlinear resonance characteristics (instability jumps, frequency hysteresis, etc), which determine effectiveness of micro-power generation. It was demonstrated that the proposed dual-resonator energy harvester favorably harnesses nonlinear resonance amplification to deliver larger average power output (up to 37 μ W) and useable bandwidth (up to 9.5 Hz) in comparison to the conventional single-resonator counterparts (delivering up to 26 μ W and up to 7 Hz, respectively). The maximum normalized power density of the device is 41 μ W cm ⁻³ g ⁻² , while volume figure of merit and 3 dB or 1 dB bandwidth-based figures of merit reach 0.18%, 11 μ W cm ⁻³ g ⁻² and 1.5%, respectively. The latter value indicates superior broadband performance of the device. Adoption of mean performance index and coefficient of variation as complementary figures of merit proved to be valuable in identifying device configuration that yields the most effective and stable broadband operation in a targeted frequency range.

This work studies the influence of high-frequency excitation of a cutting tool during end milling of workpieces made of difficult-to-cut metallic alloys. It is demonstrated that high-frequency vibrations superimposed onto the continuous movement of the tool lead to milling process stabilization with superior surface finish in comparison to conventional machining. A finite element model of the vibration milling tool was built and verified experimentally. The model treats the tool as an elastic pre-twisted structure (mill cutter) characterised by its natural vibration modes. The resonance frequencies of the axial vibration mode of cutters of two different lengths were predicted numerically and subsequently used for excitation of the vibration milling tool during cutting experiments. Qualitative and quantitative characterization of the surface quality of the machined stainless steel and titanium alloys was performed. Measurement results have confirmed that excitation of a specific tool mode is a prerequisite for achieving maximal efficiency of the vibration milling process. Statistical analysis of the collected roughness measurement data identified factors that most significantly contribute to the improved surface finish of the workpieces

The piezoelectric transduction mechanism is a common vibration-to-electric energy harvesting approach. Piezoelectric energy harvesters are typically mounted on a vibrating host structure, whereby alternating voltage output is generated by a dynamic strain field. A design target in this case is to match the natural frequency of the harvester to the ambient excitation frequency for the device to operate in resonance mode, thus significantly increasing vibration amplitudes and, as a result, energy output. Other fundamental vibration modes have strain nodes, where the dynamic strain field changes sign in the direction of the cantilever length. The paper reports on a dimensionless numerical transient analysis of a cantilever of a constant cross-section and an optimally-shaped cantilever with the objective to accurately predict the position of a strain node. Total effective strain produced by both cantilevers segmented at the strain node is calculated via transient analysis and compared to the strain output produced by the cantilevers segmented at strain nodes obtained from modal analysis, demonstrating a 7% increase in energy output. Theoretical results were experimentally verified by using open-circuit voltage values measured for the cantilevers segmented at optimal and suboptimal segmentation lines.

Due to their small size, low weight, low cost and low energy consumption, MEMS accelerometers have achieved great commercial success in recent decades. The aim of this research work is to identify a MEMS accelerometer structure for human body dynamics measurements. Photogrammetry was used in order to measure possible maximum accelerations of human body parts and the bandwidth of the digital acceleration signal. As the primary structure the capacitive accelerometer configuration is chosen in such a way that sensing part measures on all three axes as it is 3D accelerometer and sensitivity on each axis is equal. Hill climbing optimization was used to find the structure parameters. Proof-mass displacements were simulated for all the acceleration range that was given by the optimization problem constraints. The final model was constructed in Comsol Multiphysics. Eigenfrequencies were calculated and model’s response was found, when vibration stand displacement data was fed into the model as the base excitation law. Model output comparison with experimental data was conducted for all excitation frequencies used during the experiments.

This paper reports on numerical modeling and simulation of a generalized contact-type MEMS device having large potential in various micro-sensor/actuator applications, which are currently limited because of detrimental effects of the contact bounce phenomenon that is still not fully explained and requires comprehensive treatment. The proposed 2-D finite element model encompasses cantilever microstructures operating in a vacuum and impacting on a viscoelastic support. The presented numerical analysis focuses on the first three flexural vibration modes and their influence on dynamic characteristics. Simulation results demonstrate the possibility to use higher modes and their particular points for enhancing MEMS performance and reliability through reduction of vibro-impact process duration.