Study Of Ultrasonic Elliptical Vibration Assisted-cutting Micro-texturing

In this paper, for the efficiency and adaptation of the surface micro-texturing manufacturing, the ultrasonic elliptical vibration assisted micro-texturing was researched as the object. Theoretical analysis and experiment method have been used to study design of the ultrasonic elliptical vibration assisted cutting device, the control model of the micro-texturing and the simulation of micro-texturing by the ultrasonic elliptical vibration assisted cutting. The main achievements were as follows:1. The device of the ultrasonic elliptical vibration assisted cutting has been designed and modeled. The finite element method was used for the analyzation of structure's resonate frequency, vibration amplitude and the vibration stability, the final structure for the following physical experiment was selected by the comprehensive performance. The theoretical feasibility of elliptical trajectory in the tool tip was verified by the established kinematic model.2. The performance of the actual device was tested by the established test system. The resonate frequency and the vibration mode of the device, excitation phase difference response and the sine amplitude step response of the tool tip locus were tested for the verification of the actual device's reliability. The test data and the simulation result were analyzed for the verification of the design requirement. The exciting amplitude and the elliptical locus were fitted.3. The control and simulation method of the ultrasonic elliptical vibration assisted cutting device were proposed. Considering the shape and the distribution of the target micro-texturing, the cutting locus equation was established by the geometric features, the cutting parameters and the workpiece features. Considering the vibration frequency, the elliptical cutting trajectory and the cutting edge, the locus control sequence was dispersed and compensated, the control model of the ultrasonic elliptical assisted cutting device was established. Finally the simulation of surface topography of milling workpiece was established.4. A series of machining experiments had been designed by the established control model, separately cutting the aluminum 6061-T6 for the simple texture and complex texture to validate the proposed control model. Comparing the simulation results with the experimental results, the correctness of the control model and the effectiveness of the simulation system were validated.