Research On Ultrasonic Machining Technology Of Rotary EDM Ultrafine Copper Tube Electrode For Micro-Hole Machining

Rotating electric spark copper tube electrodes are suitable for machining difficult-tocut conductive materials and a large number of precise micropores on complex structures.With the increase in demand for weight reduction,heat dissipation,and ventilation of highprecision equipment,there are a large number of parts that need to be processed with various micro-holes,and there is a great demand for ultra-fine copper tube electrodes.The traditional processing of copper tube electrodes uses mechanical rolling to separate the cores.The mechanism wears seriously and the degree of automation is low.Ultrasonic machining is used to make the electrode copper tube undergo micro-plastic deformation,and the electrode copper tube can be detached from the core mold.Based on the analysis of copper tube production methods and the principle of ultrasonic rolling processing,this paper designed and builded ultrasonic machining equipment for rotating EDM ultra-fine copper tube electrodes,and conducted ultrasonic machining process test research.The main completed work in this paper is as follows:First,the mechanical structure design of the equipment is completed.Designed and selected the platform reciprocating device,rotating clamping device,tool head moving device and ultrasonic system in the mechanical structure;used ANSYS WORKBENCH software to simulate the design of the ultrasonic tool head,and Completed the modeling and interference analysis of the overall equipment,completed the construction of the mechanical body.Second,accorded to the ultrasonic machining process,the design of the ultrasonic machining equipment control system was completed.Analyzed the movement process,to be determine the overall control plan of the equipment and the software flow design of the upper and lower computer.Used Delphi and Keil5 software to design the control system;finally,accorded to the circuit principle of the ARM single chip,completed the control hardware circuit connection design,and finally completed the control hardware connection.Third,designed and completed the basic processing test.Through the backlash measurement test,the tool head movement backlash of the equipment was 9.6?m,and software compensation was performed at the same time.The copper foil single-factor test was designed and carried out.The copper foil thickness change and surface roughness were used as indicators to initially determine the processing parameter range.: Ultrasonic energy range is 6 ? 11 J,ultrasonic tool head output amplitude percentage is 60% ? 90%,platform feed speed range is 80 ? 220 mm / min,preset pressure range is 1 ? 3N.Fourth,the design completed the ultra-fine copper tube electrode ultrasonic machining test.Selected the guiding mechanism through actual processing test.Analyzed and determined the V-shaped block as the guide device to provide conditions for the orthogonal test;then conducted the copper tube electrode orthogonal processing test,analyzed the test results through range analysis and variance analysis,and the factors that significantly affect the surface roughness are from strong to Weaknesses are: preset pressure,spindle speed,amplitude,ultrasonic energy,and platform moving speed.The optimal processing parameter combination is: preset pressure is 2N,spindle speed is 1100 r / min,ultrasonic tool head output amplitude percentage is 65%,ultrasonic energy is 7J,and platform moving speed is 180 mm / min.After optimized the processing parameters,the copper tube electrode processing test of the outer diameter of the tube is 0.25 mm,which can achieve the core pulling of the tube with a length of less than 1000 mm,the surface roughness is below 0.45?m,the roundness error is controlled below 5?m,and the thickness of the tube wall is uniform Obvious defects.