Experimental Research And Numerical Analysis On The Intersection Line Of Pinhole Ultrasonic Deburring

In the mechanical processing, all kinds of irregular burrs are produced inparts surface, especially the inner surface of pinhole. Although the burrs aresmall, they have great influence on the service life of parts and assemblyaccuracy, sometimes the hazards caused by burrs are very serious.With the further research on ultrasonic machining technology and maturityof ultrasonic technology, especially the research on the processing mechanism ofthe ultrasonic machining technology in the ultrasonic machining, the ultrasonicmachining technology began to be widely used in engineering.The inner surface of pinhole ultrasonic deburring is researched in this paper.Ultrasonic machining technology was applied to the machining burr removal,reflecting the wide application of ultrasonic machining technology. In this paper,φ5mm intersection holes burrs’ removal by ultrasonic machining is mainlystudied. The main component in ultrasonic processing system____horn isdesigned and researched. The mechanism of ultrasonic deburring is analyzed.The burrs’ fracture process by using the ABAQUS/Explicit module is simulated.Finally, experimental research on ultrasonic deburring is studied.The main contents as following:1. The formation mechanism of the burr of the pinhole intersection line wasanalyzed and studied. The characteristics of some burr removal methods weresummarized. Based on the principle of ultrasonic machining，the intersectionline of pinhole burr which is formed with45steel drilling is used, the mechanism of ultrasonic deburring processing was analyzed.2. The conical ultrasonic horn, the Stepped ultrasonic horn and thegaussian-typed composite horn are designed and analyzed. The modal analysisand harmonic response analysis for three horns are made through the finiteelement analysis software ABAQUS. Comparing to the theoretical value and thevalue of simulation results of various horns’ performance parameters, it isconcluded that the finite element analysis software in the design of ultrasonichorns has very high reliability.3. Comparing to the horn for experiment and the horn of theoretical design,it is found that some structure of the horn for experiment has little impact on thehorn’s resonant frequency, such as plane structure、the screw thread structure、disc.4. The models of the abrasive impact on the burr and the shock wave to theburr by the ultrasonic cavitations are established. Using ABAQUS softwareABAQUS/Explicit simulation module to simulate the models, the burrs’ stressdistribution of the abrasive’ impact on the burrs and the impact of ultrasoniccavitations effect can be intuitively observed. The burrs’ stress distribution ofdifferent impact speed and the presence of tangential velocity are analyzed. Andthe burrs’ stress distribution of different abrasive’s impact on the burrs arestudied.5. The influence of different process parameters on burr removal efficiencyand the cause of different process parameters on burr removal efficiency areanalyzed. Selecting the amplitude、abrasive particle size and abrasive slurryconcentration as processing parameters, it is concluded that the optimum processparameters under the existing experimental condition according to orthogonalexperimental design method.