Based On The Ultrasonic Vibration System Of Ultrasonic Assisted Processing Optimization Design And Test

With the development of science and technology, different of non-traditional machining technology has gained the great attention in manufacturing industry. Under the extensive use of power ultrasonic process, design the high performance ultrasonic vibration system can improve the production efficiency. To design the high performance system, the paper study on the dynamics performance and optimal design of the system by FEM based on theoretical analysis. The mainly contents are outlined as follows:The thesis summarizes the generation of USM technology and its superiority firstly. The recent applied state of USM technology, ultrasonic vibration system and ultrasonic assisted machining are analyzed. State the foundation and meaning of this thesis.The principle, the feature and the application of USM and ultrasonic assisted machining are stated. Component parts of vibration system and basic theory of design are analysed. The optimal design theory of vibration system is expatiated.Analyze the dynamics performance of the ultrasonic vibration system, including piezoelectric transducer, transformer and transformer with tool. The parametric optimization design techniques of the finite element analysis package ANSYS are applied to optimize the structure dimension of the ultrasonic vibration system. The procedures for optimizing the geometric dimensions of the ultrasonic vibration system by using ANSYS are introduced. And have optimal design to piezoelectric transducer and transformer with tool.Improve the system of ultrasonic assisted machining. Ultrasonic device uses piezoelectric transducer and digital ultrasonic generator, which can be automated feedback and track the natural frequency changes of ultrasonic processing system, so it can assure the system to work in the resonant frequency. Verify the amplitude of vibration system by the laser-CCD sensors for micro-displacement. The optimized system can get much bigger amplitude, and the test is based on the optimized system.The machining tool applied in micro-machining field is very small; its request of accuracy is very high. Many different shapes of tool electrode are designed, such as shaft, micro-convex array, micro-gear. The manufacturing methods of micro-tool electrode are studied and perfected, such as WEDM (Wire Electric Discharge Machining), EDM "copy adding translate", combinative EDM, etc. With these means, several different micro-tools are successfully manufactured which are suitable for the request of ultrasonic assisted machining experiment. Experiments are carried by USM on different materials such as kentaniums YB151and YG8, monocrystal line silicon and piezoceramics. The test results indicate that micro-USM is an effective method for machining hard and brittle non-metal, but the working efficiency of machining hard and tough metals is very low, and the wastage of machining tool is big. Compared tests by single ultrasonic machining and ultrasonic combined electrical micro-machining in different materials are done. The test results show that the ultrasonic vibration combined electrical micro-machining has high working efficiency, good surface quality; furthermore, its micro-tool-cathode wastage is low. While ultrasonic vibration combined synchronous PECM not only has high working efficiency, but also has better machining accuracy and surface quality. Under the same electrolysis conditions, the processing efficiency of index transformer is higher than conical transformer. Index transformer is important to micro-machining field for its stability when processing, even though it has complex design and difficulties in processing.In the end, the process technology of optimal design of ultrasonic vibration system is analyzed and summarized. Furthermore, process problems, shortage and its improvement means are also suggested. Then further study works are put forward.