Rotary Ultrasonic Machining Vibration System

Hard brittle materials (such as ceramic, glass, precious stone, carbon fiber, etc.) with high hard brittle and low facture toughness characteristic make conventional processing methods questionable that being used for rotate ultrasonic machining. For example, low precision, poor performance, low efficiency and high cost. It is urgent to find high-precision, high efficiency, low-cost processing methods and the rotary ultrasonic machining method with a good performance is adopted in the circumstances. It is a compound processing method with high-speed rotation around its axis which combines the fine cutting performance of diamond material and the supersonic vibration of the tool-bar. It demonstrates great advantages in the processing of hard brittle materials. This paper focuses on one of key technologies of rotary ultrasonic machining——ultrasonic vibration system. The paper mainly includes the following parts:First, the characteristics and advantages of rotary ultrasonic machine are described; also the state of domestic and foreign rotary ultrasonic machine tool and ultrasonic vibration system are described. And the composition of ultrasonic vibration system is briefly introduction.Second, the major part of this paper is design, analysis, simulation and optimization of rotary ultrasonic vibration system. Rotary ultrasonic vibration system is designed based on one-dimensional longitudinal vibration theory that it is suitable for rotary ultrasonic machine tool. Ultrasonic vibration system includes two parts:the sandwich piezoelectric ultrasonic transducer and the tool bar. And the design dimensions are approximately obtained by applying analytical method. The natural frequency and resonant modes are gained by means of modal analysis and harmonic analysis of ultrasonic transducer, tool bar and the entire ultrasonic vibration system with finite element analysis software ANSYS. Optimization of the ultrasonic transducer is completed via applying APDL, and amplitude of tool face is bigger. Moreover, The performance analysis of ultrasonic vibration system is completed by applying the four-pole network method, and all kinds of performance indexs are gained.Finally, the main performance parameters of ultrasonic vibration system are test by applying the dynamic analyzer. The results show that the parameters meet performance index. The deviation of resonant frequency is only 0.38%. Then the ultrasonic vibration system is installed in rotary ultrasonic machine tool. Drilling and simple processing of three-dimensional surface are implemented. Experimental results show that the vibration system has a high processing efficiency and good processing precision.