Fundamental Research On Single Driven Ultrasonic Elliptical Vibration Cutting With Combined-beam Horn

Ultrasonic elliptical vibration cutting is carried out by means of making the cutting tool vibration in elliptic orbit,and the common cutting process is changed fundamentally by the ultrasonic elliptical vibration.Compared to common cutting and 1-directional ultrasonic vibration cutting,ultrasonic elliptical vibration cutting has the advantages of reduced cutting force,reduced cutting temperature,suppressed burr and reduced surface roughness,etc.In order to overcome the disadvantages of double/multi driven ultrasonic elliptical vibration cutting device with complex structure and single driven ultrasonic elliptical vibration cutting device with low structural rigidity,we carried out the fundamental research on single driven ultrasonic elliptical vibration cutting with combined beam horn.(1)We analyzed the elliptical vibration forming conditions of two harmonic vibrations,and obtained the elliptical vibration forming conditions under single driven.The mathematical model of the combined beam horn was established,and the standard elliptic equation,the X-and Y-direction amplitudes,vibration phase shifts,and elliptical vibration orbits at the output end were obtained.(2)The overall layout of the single driven ultrasonic elliptical vibration cutting device with combined beam horn is designed,and the structural parameters of a single driven ultrasonic elliptical vibration transducer are calculated.The modal analysis,harmonic response analysis,transient analysis and structural optimization of the single driven ultrasonic elliptical vibration cutting device were carried out,and the single driven ultrasonic elliptical vibration cutting device was manufactured.(3)The X-and Y-direction amplitudes,vibration phase differences,and elliptical vibration orbits were tested,and the accuracy of the elliptical vibration mode transformation mathematical model of the combined beam horn was verified.The direction of the elliptical vibration orbit,the driving force,and the stiffness at the output end of the horn were experimentally studied.(4)The micro-morphology model of the workpiece surface was established,several parameters such as the cutting speed ratio,the elliptical orbit inclination angle,the blunt edge,and the tip arc ware analyzed,and the microscopic topography model of the elliptical vibration cutting workpiece surface was verified by experiments.Experiments were carried out to investigate the influence rule of cutting force,workpiece surface roughness,workpiece surface burr and chip shape by the cutting parameters.The superior performance of single-driven ultrasonic elliptical vibration cutting with combined beam horn was demonstrated.