Research On Longitudinal Torsion System Of Metal Foil Consolidation Based On Ultrasonic Vibration

In recent years,ultrasonic consolidation forming technology has attracted the attention of a large number of researchers at home and abroad.Ultrasonic consolidation has the advantages of short consolidation time,good forming interface,no pollution during consolidation,high consolidation efficiency,and consolidation processing without too high temperature.In order to study the effects of vibration mode,pressure,temperature and amplitude on ultrasonic consolidation in ultrasonic consolidation,an ultrasonic consolidation longitudinal torsion system was established.The main research contents are as follows:The effects of longitudinal vibration,bending vibration and torsional vibration on ultrasonic consolidation are described,and the principle of two-dimensional longitudinal torsional composite vibration is achieved by opening a spiral groove in the horn.The frequency equation of the 20 kHz consolidation system is derived.Based on the frequency equation,the structural size of the consolidation system is obtained,and the three-dimensional mechanism of the consolidation system is designed by SolidWorks.Based on the finite element method,the modal analysis and harmonic response analysis of the ultrasonic longitudinal torsion consolidation system was performed by ANSYS Workbench,and the modal and required data of the consolidation system around 20 kHz were obtained.Based on the multi-objective parameter optimization design,the structural parameters of the conical longitudinal torsion composite horn are optimized,and the influence of the structural parameters of each part of the horn on the longitudinal torsional composite frequency is obtained.According to the simulation analysis,the longitudinal amplitude after optimization of the consolidation system is 18.88 μm,the theoretical calculation derivation is 18.68μm,and the optimization percentage is 1.1%.The temperature field of the consolidation system was studied to analyze the variation of the temperature field of the metal foil.Based on the temperature field theory,the ANSYS Workbench temperature field module was used to study the temperature change during the consolidation process.The study shows that when the consolidation pressure is 0.5 kN and the longitudinal torsional composite vibration displacement is 20 μm,the maximum value of the consolidation temperature field of the metal foil is the smallest,the value is 111.5 ℃;the consolidation pressure is 2 kN,the longitudinal torsion composite When the vibration amplitude is 50 μm,the maximum value of the consolidation temperature field reaches the maximum value of 216.5 ℃.The machine tool was used to make a prototype of the consolidation mechanism,and the experimental test was carried out.The longitudinal vibration amplitude of the tool head is 16 μm,and the torsional amplitudes in the x and y directions are 7.9 μm and 8.1 μm,respectively.Experiments have shown that the consolidation tool head will output different amplitudes at different voltages.At this time,the longitudinal amplitude and torsional amplitude of the tool head will be affected by the magnitude of the voltage.In this paper,the theoretical analysis of the ultrasonic consolidation longitudinal torsion system is carried out,and the structural design and simulation analysis are carried out to study the effect of longitudinal torsional composite vibration on the consolidation of metal foil.The experiment have verified the rationality of the design for the ultrasonic consolidation mechanism through carrying out the frequency sweep analysis and amplitude test of the experimental prototype,it also have showed that this structure meets the design requirement and can be applied in aviation,medical and mechanical fields.