Design And Research Of Ultrasonic Spinning Equipment

With the rapid development of High-end equipment in national defense industry, new energy technologies and so on, the requirements for the manufacturing technology of key parts become much more stringent. Because Spinning has the advantages of excellent structural integrity and overall performance, is widely used to manufacture the shielding can in AP1000, new fighter nozzle and spacecraft cowling. But spinning instability is the main restrictive factors of manufacturing precision. Our workgroup researches suggest that load is the basic factors of spinning instability. So, ultrasonic is introduced into spinning, and study and design the equipment of ultrasonic spinning. The main research content and findings are as follows:Firstly, apply the FEM software Msc.Marc to establish3-D model of ultrasonic thinning spinning, analysis find that deformation load deformation stress, friction stress of ultrasonic spinning are much less than which of traditional spinning. The feasibility of reduce load in ultrasonic spinning is proved, and design the overall structure program of ultrasonic spinning.Secondly, apply the analytic method to design ultrasonic transducer and ultrasonic horn, obtain the curve of frequency equation on transducer front end. Calculate the whole-wavelength compound ultrasonic horn by the means of stepwise design method, and derive the frequency equation of composite horn, obtain the curve of this transcendental equation. Apply the FEM method to complete the dynamic analysis to the ultrasonic transducer and horn, obtain the vibration mode. Make use of impedance analyzer to test the natural frequency and impedance, validate the effectiveness of the analytic method and FEM.Thirdly, study the coupling rules of ultrasonic horn and roller, which ultrasonic horn works in longitudinal-vibration mode and roller works in bending-vibration mode. Analyze the coupling characteristics of frequency and amplitude, Study the influence of parameters to the frequency of longitudinal-bending transformer. Based on the researches, a transformer is designed and manufactured, and is validated by test. Analyze the errors between measurement and calculation, obtain the method of correct errors.Finally, based on the research conclusions, complete ultrasonic spinning equipment is manufactured, and the experiment is conducted. It is proved that deformation load is reduced after introducing ultrasonic into spinning. This study provides basis for optimization of process and equipment, gives a feasible way for high ratio of diameter/thickness and thin rotational parts.