Research On Design And Experimental Analysis Of Non-traditional Ultrasonic Horn

With the rapid development of today’s aerospace,defense,military and other cutting-edge technology field,China’s precision and ultra precision manufacturing technology has been greatly improved.However,abnormal deep cavity,large curvature optical glass element,large size deep hole of the composite component of the overall manufacturing technology is needed to be improved in the future.And ultrasonic vibration assisted machining technology can well make up for the defects existing in the traditional precision manufacturing.And it can ensure the composite parts machining accuracy and surface quality,so much attention has been paid to the development of the ultrasonic vibration device.The key of researching and developing ultrasonic vibration system lies in the design of horn.At present,the system has failed to get better solution in non-traditional horn,this paper aiming at the problem started as follows:(1)In view of the problem that the cutting force and cutting heat is too large to reduce the machining precision and the surface quality,a new method of ultrasonic vibration system is proposed.By using new piecewise approximation approach design a suitable for deep cavity machining index transition amplitude.Then the modal analysis was carried out for the super-long index transition amplitude in finite element software,and according to the deviation between the analysis results and the target requirements was modified on the part size optimization;Flange position selection is solved by using FEA software,and the impedance analysis and vibration test of horn are optimized.The results showed that impedance characteristics and vibration performance of horn is good.(2)In order to guarantee system in the process of continuous work in good condition,the working frequency of the system,operating temperature,the effect of the vibration are tested.the result indicates that 他 he parameters of each part is normal during the long time continuous working process.In addition,there is also a test for ZTA ceramics by vibration grinding,and its grinding effect is better than that of ordinary grinding.(3)To solve surface grinding problem about large curvature optical glass,based on the theory of bending vibration,coupled vibration and horn design to design a cup tool composite horn,and then its impedance and amplitude characteristics are tested.Relationship between geometry parameters and resonance frequency effect are studied on system by the FEA.(4)According to snell’s law to design the big load and milling horn,and then using the finite element software to modify its results.Relationship between resonance frequency and geometry parameters are studied.In addition,the impedance and vibration performance are tested,the test results show that the impedance and vibration characteristics are good.