Design Of Rotary Ultrasonic Machining Equipment And Research On New Type Of Ultrasonic Horn

With the development of science and technology,various ceramic material with advanced performances occur continuously.Because it has a great deal of eximious performance such as the high rigidity,high thermal resistance,abrasion resistance and corrosion resistance,ceramic materials has been widely applied in machinery,electronics,aerospace and automotive industries etc.But the high rigidity and high brittleness lead that it is difficult to be manufactured,the application of ceramics is restricted by the cost of manufacture.It has been proved that the ultrasonic machining is the available approach to machining the rigid and fragile material such as ceramics,quartz,diamond and semiconductor.The tools of traditional ultrasonic machining are frayed largely and its precision and efficiency are low,so new machining methods are searched and new types of equipments are produced at home and abroad.It is indicated that the rotary ultrasonic machining which makes use of diamond tool and has been developed based on the traditional ultrasonic machining is an effective way to machining the rigid and fragile material.The rotary ultrasonic machining has nicer development forefront.Ultrasonic machining equipment consists of ultrasonic generator, transducer and horn.The Ultrasonic horn plays an important role in ultrasonic machining process.Its main function is to amplify the velocity and amplitude of mechanical vibration from transducer at its output end or to focus ultrasonic vibratory,energy on a small area.Amplitude ratio is an important performance parameter of an ultrasonic horn,and it has notable influence on the material removal rate of workpieces.Different kinds of horns have its own advantages, but none of them is the best.The amplitude ratio of the exponential and the conical horn are low,which reduces the machining efficiency.The amplitude ratio of the stepped horn is higher than that of the exponential and conical horn, but the abrupt change at diameter leads to higher working stress.Even if the conical or round transition is adopted to reduce working stress,the amplitude ratio will be lost.With the improvement of finite element method and the development of correlated application software,it is possible to design ultrasonic horn through computer.In this paper,from the viewpoint of enhancing the efficiency of ultrasonic machining equipment,the vibrating system of rotary ultrasonic machining equipment was designed and manufactured.Through the research on ultrasonic horn,a new type of ultrasonic horn with large amplitude ratio was designed.The main contents are as follows: 1.The ultrasonic generator with large power and piezoelectric transducer were adopted,and ultrasonic vibration system was designed and manufactured.2.Exponential,conical and stepped horns were designed by using the analytical method based on ultrasonic theory,and the resonance length,standing node and amplitude amplification ratio of these horns were obtained.3.Based on model analysis,harmonic response analysis and optimum design of ANSYS,exponential,conical and stepped horns were designed. Comparing the results using the two different ways of horn design,the validity of ANSYS is proved.4.Through applying ANSYS and taking the thrice spline curve as the generatrix of axial direction section of ultrasonic horn,the shape and resonance length of the horn are optimized simultaneously,and a new type of ultrasonic horn with large amplitude ratio was designed.5.The reliability of vibration system was proved by experimental research. The parameters such as resonance frequency,location of standing node and amplitude amplification ratio etc were tested in order to evaluate the performance of new ultrasonic horn.