Ultrasonic Vibration Electrical Discharge Machining System Analysis And Experimental Research

The paper summarizes the domestic and foreign status of micro-USM (ultrasonic machining), micro-EDM (electrical discharged machining) and ultrasonic combined electrical machining technologies, and analyzes their processing mechanism and characteristics.The characteristic of ultrasonic vibration system is optimized. Tools which used in ultrasonic combined electrical machining are designed and manufactured.Many experiments of ultrasonic combined electrical machining are carried out, the purpose is to develop a new technology of ultrasonic vibrate combined electrical machining for microfabrication technology.The system of ultrasonic combined electrical synchronous machining is built up. Digital ultrasonic device can automatic feedback and track Real-time frequency variation of ultrasonic vibration system, ensure vibration frequency of ultrasound device is in accordance with the system of processing inherent frequency points, that means electrode tool is always in the most resonant amplitude. The piezoelectric transducer which is used in the system has better stable property and smaller size than traditional magnetostrictive transducer. In the process of machining, there is not temperature-rise which is caused by hysteresis effect, System will be more stable. Adjustable magnetic tension bench with creep feeding mechanism is used to maintain optimal working pressure.Ultrasonic synchronous chopper is designed and improved, which can supersonic chopped to discharge processing power, and get high-frequency pulse electric tension of ultrasound synchronous discharge.In other ways, by using precise and high-speed laser micro displacement sensor to measure the distance between workpieces and tools, connect with the chopper and control of electric power. Discharge machining pulse of the two kinds of synchronization method are perfect according with Super audio vibration frequency and phase, the result shows that the two kinds of synchronization method have the same processing effect. The price of precise and high-speed laser micro displacement sensor is very high (more than8000dollars) and the method of Ultrasonic synchronous chopper can greatly reduce the cost of system, the synchronous rapid chopping power has applied for invention patent.Using ANSYS software to optimize ultrasonic vibration system and make parameters calculation and dynamic analysis study to amplitude transformer horn. In the process of modal analysis, get their inherent frequency;In the process of harmonic response analysis, get the response accord with their inherent frequency, then get their displacement node, amplification coefficient and the biggest strain point, compared with parameter calculation,they fit better with each other. It sets up a good foundation for the use of amplitude transformer horn.On the one hand, considering the test have no specific requirements to the amplification coefficient of amplitude transformer horn, on the other hand, considering the easy manufacture, cone shape amplitude transformer horn with tool cathode is designed. In the process of modal analysis, get the inherent frequency near20KHz; in the process of harmonic response analysis, get the response under inherent frequency,and then get the amplification coefficient displacement node and great strain point.In the end, improve relevant parameters According to the results of analysis. Taking advantage of laser micro displacement sensor to detect the amplitude of the three types of transformer, the results are perfect accordance with the results of dynamics analysis. The result shows the index transformer has the best processing stability.From the point of test and measure to prove the positive relation between Ultrasonic machining power and amplitude of electrode end face.In order to proving different materials have different influence to processing result, used same parameter to do some test,and contrast and analysis. Many experiments of ultrasonic combined electrical synchronous machining are carried out, compare with ultrasonic machining, illuminate the technology advantage of ultrasonic combined electrical synchronous machining, and summarizing the technical characteristics of ultrasonic combined electrical synchronous machining.In the end, the technical characteristics of ultrasonic combined electrical synchronous machining are analyzed and summarized. Putting forward the existing problems and perfect plans, that will be good prepared for the subsequent works.