The Mechanism And Experimental Study Of Axial Ultrasonic Vibration Assisted Grinding

High temperature alloy,functional ceramics,composite materials and other advanced materials have been widely used in aerospace,shipbuilding,nuclear power,automotive,electronics,medical and other fields.According to the quickly extension of the advanced materials application,the problems of material processing comes subsequently.Advanced materials processing technology contains the machining methods of difficult-to-machine materials,such as alloys,ceramics and composite materials.The processing method is the core technology of processing and manufacturing industry.Ultrasonic vibration assisted machining technology is a kind of precision,effective method of advanced materials processing,which attracting more and more attention of the researchers.Study on ultrasonic vibration assisted machining and revealed the principle of ultrasonic vibration assisted machining is the basic way to solve the high precision machining problems in advanced materials processing.Ultrasonic vibration assisted machining including ultrasonic vibration assisted grinding,turning,milling,drilling and other processing modes.Ultrasonic vibration assisted grinding(UAG)has broad application prospects,which is widely used in the surface molding and material removal,etc.Theoretically study on the processing mechanism of ultrasonic vibration assisted grinding plays a decisive role in design of ultrasonic vibration equipment,optimization of ultrasonic machining process and improve the quality of ultrasonic machining.At present,the application of UAG is masterful used on the engineering practice,but the problems in machining mechanism research and the system-matching between the ultrasonic vibration system and machine tool system are unsolved.In order to solve the problems in UAG,following aspects were studied in this paper:1)Research on the ultrasonic vibration system,which including the design of ultrasonic horns,the design of ultrasonic cutting tools and the finite element simulation of ultrasonic horns.Revealed the problems in the actual application of ultrasonic vibration system and propose solutions from the design level.2)Research on the processing mechanism of axial ultrasonic vibration assisted grinding(AUAG),which including kinematics analysis,grain trajectory model,material removal rate model,grinding force model,etc.3)Study on AUAG for plastic material processing,presented the definition of system matching between ultrasonic system and machine tool system.Integrate the function parameters of ultrasonic vibration system into machining process for the first time.Established the system matching model and reveal the influence of ultrasonic parameters on grinding quality.4)For hard and brittle material processing,theoretically described the mechanism of ultrasonic machining and established the system matching model.Explain the grinding force in ultrasonic machining and the formation mechanism of the surface morphology in AUAG;finally verify the effect of ultrasonic machining.5)Ultrasonic vibration filing(UVF)is used to improve the processing quality in the C/SiC components.The research method of machining mechanism in brittle materials processing is used to determine a set of scheme of ultrasonic machining for composite materials processing.The surface damage is investigated for improve the machining quality,and its feasibility is verified by experimental research.