The Foundation Research On Numerical Controlled Rotary Ultrasonic Machining Technology

Now, ultrasonic machining is a effective method to machine hard and brittle materials, such as glass, diamond, engineering ceramics, etc. The traditional ultrasonic machining method can be used mainly in drilling holes and copying machining. Although it can be used to process complicate-shaped components, tools with concave-convex reversed cavity is needed. But it causes a lot of problems, such as manufacturing complexity, high cost of processing, long cycle time and high abrasion in processing. So it can not satisfy the demands of modern manufacturing. The target of this thesis is to find a way to combine rotary ultrasonic machining with the opening numerical controlled system based on PMAC and realize the machining of complicate-shaped components.The numerical controlled rotary ultrasonic machining machine is based on the bed of milling machine, on which three precise working tables are installed, and a rotary ultrasonic vibrating device is designed. In processing, the tool can not only rotate but also vibrate. In order to measure the cutting resistance, the cantilever heavy sensor was installed on the bed. Numerical controlled system called the distributed-dual CPU structure adopts the industry PC (IPC) and programming multiple-axis controller (PMAC) which complete the control center of the system. The coordinate axis was actuated by the servo unit which was controlled by the PEWIN3.20 PRO software. The numerical controlled ultrasonic machining system can complete the machining of complicate-shaped components theoretically.In order to discuss the ultrasonic machining craft rule of aerosol abrasive, the material removal rate experiments and the cutting resistance experiments had been done, we learned that the influence of the layer depth and the traverse speed on the MRR and cutting resistance is obviously, and the fitting rotary speed and abrasive will make a better processing effect. All of these provide the theory basis about how to select process parameters for practical production. And the three-dimensional concave which manufactured by the numerical controlled rotary ultrasonic machining proved the feasibility of processing complicate-shaped components. Meanwhile, the analysis of the mechanism of the material removing will buildes the foundation in the following research.Compared with traditional ultrasonic machining, the numerical controlled ultrasonic machining makes the control of machining process much simpler, without producing complex tools. As well, the flexible performance of all machine system is increased and the machining cost is decreased.