Design And Application Of Large Amplitude Ultrasonic Luff In Cutting Honeycomb Materials

Ultrasonic cutting technology is widely used in the actual production and processing of honeycomb composites because it has unique advantages in processing honeycomb composites and can effectively overcome the problems of traditional processing methods.However,in the actual processing process,the phenomenon of cracks in the horn at the point of maximum stress often occurs.At the same time,traditional horns can hardly meet the needs of enterprises with large amplitudes.In the past,the design of horns rarely considered the load bearing system Optimize the horn.Based on the above problems,this paper designs a large-amplitude luffing rod based on the traditional analytical method to meet the needs of actual production and processing.The genetic algorithm is used to optimize the size parameters of the luffing rod under the consideration of the tool load.Based on the combination of ANSYS numerical simulation and single factor experiment under dynamic load,the flange structure of the luffing rod was optimized,and the experimental results of the optimized design were verified.The specific research contents of this article are as follows:(1)To meet the requirements of ultrasonic cutting of honeycomb composite materials,a large-amplitude horn with small working stress is designed.Based on the wave equation,a conical transition composite horn theoretical model was established.The influence of structural parameters on the comprehensive performance parameters of the horn was analyzed.Through a comparative analysis,the design scheme of the cone transition composite horn with the same length and length was determined.The analysis results of the amplitude magnification and shape factors show that the structure horn can meet the requirements of the actual processing amplitude,and at the same time,the comprehensive performance is superior.(2)The finite element analysis technology is used to verify the rationality and superiority of the designed horn.Using ANSYS Workbench software to simulate and analyze the precise model of the horn,verify the accuracy of the analytical model of the horn design;use simulation technology to study the maximum stress of the horn under no-load condition,and verify the designed size Luffers with the same end length not only meet the requirements of actual processing,but also have good durability.(3)The influence of tool load as static load on the optimized design of horn is studied.The influence rule of the thickness and length of the load cutter on the resonant frequency and displacement node of the horn is analyzed,and the actual target requirements for the size optimization of the horn are proposed;As a design variable,a multi-objective optimization model was established with the resonance frequency,node position,and amplitude magnification as the optimization objectives to optimize the dimensional parameters of the horn,which significantly improved the performance parameters of the horn.(4)The effeect of dynamic load on the optimized design of the horn is studied.Considering the effect of dynamic load on the horn,based on the combination of ANSYS numerical simulation and single factor experiment,the flange structure of the horn is optimized and the number of U-shaped grooves is determined when the flange thickness is 5 mm 6.Luffing rods not only have high ultrasonic transmission efficiency,but also have good structural rigidity.(5)Perform performance test research on the designed horn.Through impedance analysis experiments and amplitude tests,the related parameters such as the resonant frequency and amplitude magnification of the horn are verified,and the accuracy of the finite element analysis is verified.The designed horn has good stability performance;the micro-scanning observation of the quality of the cut surface of the honeycomb composite material has verified its good processing effect.