Design And Study Of Ultrasonic Horn For Titanium Ti-6AL-4V Machining

Titanium alloys have a wide range of applications in the aerospace,biomedical and marine industries due to their unique properties such as high strength,exceptional corrosion resistance and high strength-to-weight ratio.However,because of the high hardness of the material;it is difficult to process by cutting,which limits the application of this material in practice.The electrolytic method can effectively remove the material on the surface of the titanium alloy,but during the processing,a passivation film is formed on the surface of the material and the erosion rate of the material is greatly reduced.The ultrasonic assisted electrolytic machining is a new type of composite processing method due to high frequency vibration.Addition can eliminate the passivation film produced on the surface of the material during electrolytic processing,thereby ensuring the processing efficiency and quality.The horn plays an extremely critical role in ultrasonic assisted electrolytic machining,and its research directly relates to the normal processing.Based on the above analysis,this project carried out the design and research of the horn used in ultrasonic electrolytic composite processing of Ti-6Al-4V,which mainly includes the following three parts:(1)Horn design,modeling and model analysis and numerical simulation;(2)Study the various effects of process parameters on the output through the establishment of a finite element model;(3)Comparison between numerical simulation results and measurement results.Firstly,the horn was designed and modeled in Ansys.Based on the analysis results,the real shape of the horn(45# steel)was used.Then the finite element analysis based on thermo-mechanical coupling was performed in the Deform-3D analysis software.The design and production of horns provide theoretical support.In addition,the reliability of the vibration of the horn is analyzed and studied through the test.The resonant frequency and amplitude magnification of the designed new horn are measured,and the performance of the horn is tested.The design is mainly based on the basic principle of mechanical harmonic vibration,and the wave equation and the design theory of the variable amplitude rod of the transmission.Then,the horn is fabricated according to the optimized parameters.Finally,the vibration performance of the horn is evaluated with an impedance analyzer.