Research Of The Cup Tool Horn Vibration System

Ultrasonic processing has been widely used in all kinds of engineering fields, which shows great superiority over the traditional processing, especially in the precision processing of semiconductors and non-conducting nonmetallic hard brittle materials. Ultrasonic vibration aided grinding is one of ultrasonic processing methods, which has greater advantage in increasing material removal rate and making the quality of processing surface higher compared with the traditional grinding.Cup grinding tools are widely used in the processing of hard brittle materials, such as the ultrasonic vibration aided grinding of parts’surface, the nesting processing of the large diameter hole and the cylindrical bar. But the size of the cup grinding tools are always big, which has big effect on the vibrating condition of the ultrasonic vibration system. So for getting an accurate resonant frequency, stable and average output, integrated design of the horn and the cup grinding tool is proposed.This article is based on the longitudinal-bending mode transition of the ultrasonic in the vibration system, which performs a theoretical design, finite element simulation and develops a design software for the cup tool horn vibration system. The main work and results are as follows:1. According to the structural characteristics of the cup tool horn vibration system, analysis has been performed on the ultrasonic vibration mode in the thin disk of the vibration system, the bending mode displacement equation of the thin disk is given, eventually the mode transition form of the ultrasonic in the vibration system is. figured out. Based on the mode transition form and combined with the displacement equation of the vibration system’s three parts and their relevant boundary conditions, using the traditional horn design method the frequency equation of the vibration system is derived. With the default material attribute parameters and size parameters bringing into the derived frequency equation, the theoretical design of the vibration system is finally accomplished.2. Finite element simulation is performed using ANSYS on the vibration system that has been theoretically designed, the modeling parameters are from the default material attribute parameters and the derived size parameters, simulation type is chosen as the mode analysis. The analysis results reveal that the vibration system performs quite good vibrating condition and the magnification factor is quite big. The simulation resonant frequency(22370Hz) is quite close to the theoretically designed resonant frequency(25000Hz), proving the mode transition theory of the vibration system. 3. The vibrating condition testing experimental platform for the designed vibration system is set up, the platform is made up of ultrasonic generator, piezoelectric ceramic transducer, cup tool horn vibration system, laser displacement sensor and oscilloscope. The measuring results show that the amplitude of the output surface is6μm, the resonant frequency the vibration system is20223Hz which is a little lower than the simulation resonant frequency, the vibrating condition of the vibration system is excellent, the amplitude of the output surface is quite even. The experimental results correspond perfectly with the results of finite element simulation and theoretical design.4. Based on the combined use of the MATLAB and ANSYS, a horn design software has been developed. This software is used for the theoretical design and finite element simulation of the cup tool horn vibration system and other common types of horns, it provides friendly interface, convenient operation and strong function.