The Design And Research Of A Three Dimensional Ultrasonic Vibration Machining Device

With the development of China's mechanical industry,the precision of mechanical parts is becoming more and more important.In the field of machining difficult materials and complex surface,the effect of traditional machining is not ideal.The prospect of ultrasonic vibration assisted machining is good,it can significantly improve machining stability,expand the processing scope,improve the functionality of the workpiece surface.Compared with other processing methods,it has obvious advantages.The resonant type device has a higher working frequency,which can significantly reduce the main cutting force during the cutting process and improve the tool life and machining accuracy to a certain extent.At present,the two-dimensional resonant processing method has poor adaptability to complex surface processing,the three-dimensional resonant machining method can make up for this shortcoming,but it has the problem of low machining precision,which limits the application of the processed workpiece.The reason is the lack of research on three-dimensional vibration track,affects the machining precision of workpiece.Therefore,in order to meet the needs of more depth research on ultrasonic vibration assisted machining,This paper explores the principle of three-dimensional vibration machining,analyzes the influence of vibration track on workpiece morphology,proposes a three-dimensional resonant vibration machining device,and studies the machining effect of the device.The main research content of this paper includes:(1)The principle of three-dimensional vibration aided machining is analyzed.First of all,the principle of ultrasonic vibration assisted machining is described;the synthesis rules of harmonic motion with same frequency and harmonic motion with different frequency are analyzed by using MATLAB;a three-dimensional vibration machining method is proposed,the effect of the path of harmonic motion with the same frequency and that of different frequency on the surface topography is analyzed by MATLAB.(2)The overall design of three-dimensional vibration machining equipment is carried out.On the one hand,the principle of constant parameter vibration machining device is expounded and its structure design is given;the vibration analysis of the horn is carried out,analyses the relations in structure parameters,vibration parameters and the magnification factor,the change of vibration mode of horn by diagonal slits,complete the structural design of three-dimensional horn;the design example of three-dimensional horn is given.On the other hand,the principle of variable parameter vibration machining device is expounded,a realization method of variable parameter is proposed,the working frequency of the device is changed by the method of frequency modulation of electric load,and the static matching circuit is designed to make the ultrasonic generator and transducer match well at each working frequency.(3)The simulation analysis of three-dimensional vibration auxiliary machining device is carried out.The mode and transient characteristics of the transducer are analyzed by ABAQUS;the modal characteristics,transient characteristics and vibration track of the horn are analyzed by ABAQUS;the effect of vibration track of the device on the surface topography was analyzed by MATLAB.(4)The performance of ultrasonic vibration machining equipment is tested.The experimental platform of the three-dimensional elliptical vibration equipment is built,the performance of the designed ultrasonic vibration processing equipment is tested by an impedance analyzer.In order to understand the impedance characteristics of the horn,the theoretical resonance frequency(20kHz)is compared with the measured resonance frequency,and the admittance circle of the amplitude transformer is analyzed.