Development Of A Rotary Ultrasonic-vibration Grinding Tool System

With excellent physical and mechanical properties, hard and brittle materials arewidely used in many fields. However, brittle fracture are easily happened in itsmachining process because of the high hardness and brittleness. So far, ultrasonicmachining is one of the efficient and precision machining methods in hard brittlematerials manufacturing. However, abrasive ultrasonic machining has low efficiencyand serious tool wear. Workpiece ultrasonic vibration assisted machining is onlyapplicable to the workpiece with small volume and quality, limiting its application fields.In order to solve the above problems, considering the ultrasonic-vibration theory, arotary ultrasonic-vibration grinding tool system was developed in this thesis.Based on the theory of ultrasonic-vibration, the overall design of the system wascarried on, and the vibration forms of the vibration of the spindle were established.According of mason equivalent thought, an electromechanical equivalent networkmodel was proposed, and the resonance frequency equation of the spindle are obtained.The structure of the spindle was designed with the help of the resonance frequencyequation. For optimal the structure of the system, the method of finite element analysis,modal analysis and harmonic response analysis and piezoelectric coupling analysis wascarried on with different voltages.By the analysis of the impedance characteristic of the system, the resonancefrequency and the resonant frequencies was obtained. The resonance frequency was27.4kHz, which was in a reasonable range. In addition, the LK-G5000was used tomeasure the amplitude of the system. Measurement results showed that the vibrationform of system was a second-order longitudinal vibration, and the form of the grindingwheel was a bending vibration.The grinding experiment was carried out to research the influence of power supplyparameters. It turned out that, the system has advantage in improving surfacemorphology and reducing the roughness of the workpiece. In addition, for the selectedfour groups parameters, with the increase of the voltage, the quality of the workpiecesurface was improved.