Study On The Mechanism Of Ultrasonic Polishing And The Design Of Ultrasonic Horn

During the research, we find the mold manufacturers eagerly need a new kind ofpolishing equipment with high processing efficiency which is not depend on the worker’sskill. Especially about the injection mold, it is the bottleneck to improve the mold surfacequality of mold processing. Ultrasonic polishing technology is an effective mold finishingtechniques, and an ultrasonic automatic polishing method is developed to solve the aboveproblem.The principle of ultrasonic automatic polishing is that the ultrasonic generatorgenerates the ultrasonic vibration which is transmitted to the horn through the transducer,and then the horn drives the abrasives in abrasive suspension after the horn amplifies thevibration amplitude so that the abrasives hit surface of mold to decrease the roughness ofthe surface.Some basic work has been done in the polishing mechanism for elastic-plasticmaterial that mold steel belongs to, where little research has been done until today. Inaddition, ultrasonic horn is a very critical part in ultrasonic polishing. New equipmentdemand the horn that is not sensitive to the frequency fluctuations caused by externalchanges or replacement of the tool head linked to the horn, this article will also focus onthis area. A complete set of solutions of design and optimization of the ultrasonic automaticpolishing horn is provided.The relevant researches and applications are summarized and the following researchesare carried out.(1)The ultrasonic automatic polishing system’s main components are designed, thevarious parts of the structure and function are described, and the piezoelectric transducer isselected as the ultrasonic polishing system transducer.(2) A new ductile materials removal mechanism model in ultrasonic machining isestablished, the values of the reference experiment and those of theoretical predictionsmeet very well, which lay the foundation for further research. (3) Four kinds of single-type horn are studied, three sections composite horn designformulas are derived, the dynamic characteristics of various types of horn are analyzed,and the amplification factor and stability of different horns are studied.(4) A composite assembly horn adapted to the frequency adjustment is proposed isproposed, the amplification factor of the conical horn is optimized, the optimal designmethod to the resonance frequency horn is created, which provides an accurate andefficient design solution for horns used in different conditions and the effect of the wear ofthe tool linked to horn is studied, the impact of tool head wear and the replacement of thetool head for the horn system is analyzed.