| Ultrasonic processing is an efficient and fine processing method for hard and brittle materials,and has been widely used in engineering.Ultrasonic auxiliary machinery(grinding,milling,etc.)uses ultrasonic vibration effects to effectively reduce cutting force,cutting heat,and improve machining efficiency and accuracy;electrochemical machining has the unique technical advantages of high efficiency,good surface quality and no cathode loss.The electrical discharge machining process is stable and accurate.This paper proposes a new method of rotary ultrasonic composite mechanical-electrolytic-discharge machining,trying to organically combine the ultrasonic effect with the mechanical,electrolytic and micro-spark discharge effects to achieve precise and efficient machining of difficult-to-machine materials and special-shaped parts.The main research contents are:(1)Design a rotating ultrasonic composite electrolysis-electrolysis-discharge machining system.Adopt frequency converter,AC motor,ultrasonic vibration device,design and build rotary ultrasonic electric spindle;design composite machining fixture,power supply introduction,electrochemical anti-corrosion and system electrical insulation scheme,adopt high-frequency narrow pulse power supply,ultrasonic chopper and information detection The control system is used to construct a rotating ultrasonic electrolysis-discharge device;the design uses a driver and a servo motor to construct a numerical control multi-axis linkage feed device;the design uses a radial ultrasonic vibration device and a rotating axial ultrasonic vibration device to construct a two-dimensional ultrasonic vibration system.Realize two-dimensional rotary ultrasonic mechanical-electrolytic-discharge machining.(2)Based on the theoretical basis of material mechanics,Faraday's law of electrolysis,ultrasonic mechanism,etc.,according to the interaction relationship of rotating ultrasonic,high-frequency pulse electrolysis and micro-spark discharge,the mechanism of material removal in the cooperative machining of rotating ultrasonic machine-electrolysis-discharge is studied,and the mathematics is established Model;from the analysis of the model,it can be seen that the increase in spindle speed,ultrasonic amplitude,electrolysis voltage,abrasive hardness/particle size can improve processing efficiency;and the use of high-frequency narrow pulse power supply reduces the voltage amplitude,reduces the processing gap,and reduces the electrolyte concentration,Reducing the abrasive grain size can effectively improve the processing accuracy.(3)Optimize the design of the rotary ultrasonic vibration system.Perform theoretical analysis and design calculations on piezoelectric transducers and amplifiers.The ANSYS piezoelectric analysis module is used to analyze the modal and harmonic response.When the resonance frequency is 19.8 kHz,the resonance output amplitude of the ultrasonic vibration system is 25.5 ?m.When the cathode is actually processed,the natural frequency of the vibration system will be reduced.Using ANSYS optimized design,the output amplitude of the system can reach 23 ?m,and the measured resonance amplitude of the laser micro-displacement sensor can reach more than 20 ?m,verifying that the ultrasonic vibration system design can meet the processing requirements.(4)Select cemented carbide,PZT piezoelectric ceramics,stainless steel and other materials to conduct copy ultrasonic composite machining and rotary ultrasonic composite machining experiments to explore the influence of rotary ultrasonic machining parameters on machining accuracy and efficiency;optimize machining parameters for aluminum Carbide-based silicon carbide ceramics(AlSiC)are subjected to two-dimensional rotary ultrasonic composite mechanical-electrolytic-discharge machining tests of planes and grooves,and smooth planes and grooves are processed to verify that the rotary ultrasonic composite electrolytic-electrolytic-discharge machining can achieve high-efficiency and precision machining Technical advantages. |
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