Hard And Brittle Materials Shaped Surface Ultrasonic Micro-finishing Process

Ultrasonic machining(USM) is considered to be an effective technique in processing of hard and brittle materials, particularly non-conductive hard and brittle materials, This article outlines the development of the ultrasonic machining technology and micro-ultrasonic machining history and research status, and explains the technical advantages and limitations.This article discusses the mechanism of ultrasonic machining, analysis of ultrasonic cavitation and its removal rate of ultrasonic processing of materials, machining accuracy and surface roughness of the law; in the resolution to remove the materials in ultrasonic machining speed Miller and Shaw based on the mathematical model , a new material removal rate of ultrasonic processing of the mathematical model, discusses the material removal rate of ultrasonic machining factors, while the argument from the mechanism of the process parameters on ultrasonic machining speed, surface roughness and processing quality of the law.Designed and produced a ladder-shaped and two special exponential horn, ultrasonic machining of different materials to meet the ultrasonic vibration amplitude on the request; describes three basic ultrasound machine working principle of the micro-displacement composition table, creep feed and the stability of the principle of feed pressure; given micro-ultrasonic machining efficiency, accuracy and surface accuracy of the measurement method; build and improve the micro ultrasonic machining system.Micro-tool head size small, high precision, making it difficult to design and product micro-ultrasonic machining is the key technology. This design micro shaft, micro hole, micro bar slot, step holes, micro-array axis (round, square, diamond) and so the shape of the tool head end, using micro-EDM wire cutting, EDM "anti-copy + translation" the successful combination of electrical discharge machining to produce a variety of tool head, shaped to meet the test requirements of surface micro-ultrasonic machining.Ultrasonic machining of micro holes for different feed pressure test, the workpiece and the tool contact pressure between the micro has the lowest value, then the maximum processing speed; different abrasive characteristics of ultrasonic machining stepped shaft test and analysis show that the impact of abrasive particle size and hardness processing efficiency and accuracy, but different particle size corresponds to a reasonable need to feed pressure and ultrasound amplitude, to achieve good precision, or high efficiency; tiny holes with different materials, fine bar, narrow channel and micro-array micro-pits ultrasonic machining tests and tests indicate that materials processing precision, surface quality and processing efficiency, and closely related material properties, material strength and fracture toughness of the higher frequency vibration in the ultrasonic impact and cavitation, less brittle fracture surface removal , the higher machining accuracy and surface quality, lower processing speed; ultrasonic machining hard and brittle non-metallic materials are shaped surface micromachining is an effective method with high processing efficiency, accuracy and surface quality.This article also shaped surface on the different characteristics of materials (piezoelectric ceramic, steel, carbide, etc.) ultrasonic machining and ultrasonic test ECM comparison test showed that ultrasonic electrochemical machining of carbide and other hard-ductile conductive material has a smaller the tool wear, higher processing efficiency, better precision and surface quality.In the end, the process of the main issues arising in testing were analyzed and summarized, and made follow-up research ideas and outlook.