Development Of Vibration System For Ultrasonic Composite Electrolytic Machining And Study On Material Removal Efficiency

With the development and progress of science and technology, high-tech products to develop in the direction of miniaturization and high precision. As new materials constantly adopted, the material becomes more and more difficult to machine, the machining accuracy and surface roughness requirements also become more and more high. For these problems, ultrasonic composite electrochemical machining technology with unique advantage, its research and application have become the international manufacturing industry. According to the situation of ultrasonic composite electrochemical machining technology, put forward the ultrasonic vibration system is designed, optimized and developed and the material removal model analysis and research as the paper research content.After analysis of the two traditional design method of ultrasonic vibration system, paper proposes a new method of ultrasonic vibration system design. According to the ultrasonic composite electrochemical machining technology on the requirements of ultrasonic vibration, design of piezoelectric transducer, a variety of the amplitude transformers and tool electrodes. Analysis and calculate the vibration displacement of magnetic levitation workbench, then compared with the actual test results and found two numerical approaching and small. So the vibration of the workbench can be ignored in the processing. In addition, by increasing the workbench stiffness coefficient can reduce the amplitude and the processing become more conducive.Using ANSYS piezoelectric coupling module, study the relationship between the piezoelectric ceramic piece number of the transducer and the output displacement amplitude. The exponential ultrasonic vibration system and stepped type ultrasonic vibration system are conducted in dynamic analysis (including modal analysis and harmonic response analysis). The node displacement, the maximum point stress, the vibration amplitude of end face of tool electrode of vibration system and other parameters are obtained in ANSYS post-processing module. These parameters compared with the theoretical calculation value found that the exponential ultrasonic vibration system is better than the stepped appearance ultrasonic vibration system. Optimize the exponential ultrasonic vibration system and the stepped appearance ultrasonic vibration system. According to the optimized production of ultrasonic vibration system, the optimize vibration amplitude of end face of tool electrode are measured with laser micro displacement sensor detection, then compared with the finite element analysis results. After optimization of ultrasonic vibration system can well meet the requirements of complex electrochemical machinin.Based on the indentation fracture mechanics, in view of the hard brittle materials to establish the mathematical model of ultrasonic machining material removal rate, then analysis the relationship between the material removal rate and all kinds of the electric parameters. According to Faraday’s law to establish the material removal rate of pulse electrochemical machining model of hard toughness conductive material in the condition of low voltage, low electrical conductivity, high frequency pulse, then analysis the relationship between the material removal rate and all kinds of the electric parameters.Research the influence law of ultrasound, electrolytic process and its mutual synergy mechanism, establish a mathematical model of ultrasonic composite electrochemical machining material removal rate, then analysis the role of ultrasonic and electrolysis in ultrasonic composite electrochemical machining.Making use of the combined machining technology to make a variety of tool electrode and Using the ultrasonic vibration system do single ultrasonic machining and ultrasonic composite electrochemical machining experiments. Different processing parameters (material properties, voltage, duty ratio, concentration of electrolyte etc.) can be obtained by experiment about the influence of the material removal rate, then verify the validity of the model. Through contrast test of single ultrasound machining with ultrasound composite electrochemical machining, then discuss the relations of single ultrasound, pulse electrolysis and compound ultrasonic electrolysis.Finally, paper summarized the design and test of ultrasonic vibration system, puts forward to the suitable conditions, problems and improvement measures of the existing system and the removal rate model.