Mechanism Analysis Of Ultrasonic Machining Based On LS-DYNA3D Finite Element Nethod

With the development of science and technology, advanced engineering ceramics plays an increasingly important role in the modern manufacturing industries. Engineering ceramic materials have many attractive properties such as high hardness, high thermal resistance, corrosion resistance, chemical stability and low electrical conductivity, etc. The combination of these properties makes engineering ceramics suitable for a wide range of applications, such as in machinery, electronics, aerospace, automotive, and cutting tool industries. Ultrasonic machining is used extensively in the machining of high-performance composites, ceramics, quartz, diamond and semiconductor.In ultrasonic machining, mechanism that material is removed by abrasives has no uniform conclusion so far. Because abrasives are too small, vibration amplitude of the tool is only some dozens of micrometers and work frequency is up to 20kHz, So it is impossible to observe abrasive work situation. With the rapid development of computer technology, numerical simulation becomes an indispensable approach for analyzing and solving engineering problems. Recent years FEM (finite element method) is being more and more extensively used due to the advantage of convenience, high precision, short cycles and broad suit.In this paper the mechanism of ultrasonic machining and the performance of horn are investigated based on enhancing material rate. The main contents are as follows:Firstly, two mechanics models are proposed on contact mechanics and rupture mechanics. One is at a point of contact in the elastic half-space. The other is at an ellipse area of contact. We also researched the material rupture production on impress mechanics model and energy.Secondly, mechanism of ultrasonic machining is researched by LS-DYNA3D software. In this paper we introduce the FEMB software and the process of numerical simulation. We analyze the deformation of work piece and stress distribution. We study the result between numerical simulation in the computer and electricity scan in the lab.Thirdly, a composite horn is designed by finite element method based on ANSYS software. The dynamic analysis mainly includes two aspects: mode analysis and harmonic response analysis. In mode analysis, work frequency of the horn is obtained within the range of excitation frequency. Harmonic response analysis for the horn is conducted and the amplitude of the output end of the horn is obtained. Therefore, the amplification factor of the horn is calculated. Finally, based on the analysis of theory and numerical simulation sorts of machining parameters are researched by experimental equipment. And obtain the best assembled machining parameters by many experiments.