Research And Design Of Giant Magnetostrictive Ultrasonic Vibrication Device For Progressive Forming Of Sheets

Ultrasonic vibrating sheet progressive formiing is to apply ultrasonic vibration to the tool head on the basis of the incremental forming of ordinary sheets,which can improve the forming limit of the sheet,reduce the forming force,reduce the rebound of the sheet,and improve the surface quality of the parts.Ultrasound vibration system generally includes ultrasonic generator and ultrasonic vibration device.The design of ultrasonic vibration device has a direct impact on the effect of ultrasonic processing.Research and design of high power,large amplitude,stable performance of ultrasonic transducers is of great significance to the development of the entire ultrasound field.A conical transition stepped composite horn with a tool bar was designed,and a rod-shaped giant magnetostrictive transducer and a window-shaped giant magnetostrictive transducer,a half-wavelength giant magnetostrictive transducer were designed.The dynamics simulation analysis of the transducer and the horn is carried out,and the horn is optimized to verify the correctness of the design.The bias magnetic field and driving magnetic field of the transducer were designed.In order to reduce the heat generation of the transducer,a cooling system is designed to cool the transducer.The magnetic analysis of the giant magnetostrictive transducer was carried out by using ansoft Maxwell finite element software.The influence of the magnetic path gap on the magnetic field intensity and magnetic field uniformity in the GMM(Giant Magnetostrictive Material,GMM)rod was studied.It is found through simulation that the magnetic path gap is inversely proportional to the magnetic field intensity and magnetic field uniformity in the GMM rod.When the groove width of the magnetic conductive cylinder is 6 mm,the magnetic field uniformity in the GMM rod is the highest.And when the thickness of the magnetic conductive sheet between the permanent magnet and the GMM rod is about 1.6 mm,the axial magnetic field intensity and magnetic field uniformity in the GMM rod are the highest.In order to reduce the eddy current loss of GMM rods,the eddy current losses of GMM rods with different structures are simulated and analyzed.The results show that the eddy current loss can be effectively reduced by GMM rod slicing treatment and radial slitting treatment,and the slicing treatment is effective.The various losses of the rod-shaped giant magnetostrictive transducer were analyzed and calculated.The thermal analysis of the giant magneto strictive transducer was carried out using Workbenchl5.0.It was found that slicing the GMM rod and cutting along the radial slit can reduce the temperature of the GMM rod in the transducer.but the GMM rod slicing treatment is more beneficial to reduce the temperature inside the rod transducer.In order to realize the power transmission of the ultrasonic vibration device,a current collecting ring and a non-contact power transmission device are designed.The core structure size,number of coil turns and wire diameter of the non-contact power transmission device were designed and calculated.The ansoft Maxwell finite element software was used to simulate the no n-contact power trans mission device,which verified the correctne ss of the design.The outp ut of the window transducer was studied by using manganese-zinc ferrite and permalloy as the core.When the manganese-zinc ferrite was used as the core,the output amplitude of the window-shaped transducer was large.Therefore,manganese-zinc-iron Oxygen is more suitable as a magnetic conductive materialA rod-shaped giant magnetostrictive transducer,window giant magneto strictive transducer and a half-wavelength giant magnetostrictive transducer were fabricated,Three types of transducers were tested.After adding a magnetic conductive material between the permanent magnet and the GMM rod of the rod-?haped transducer,the amplitude stability of the rod-shaped transducer is improved,and the output amplitude is increased;Axial slotting treatment of the magnetic cylinder of the rod transducer,When the groove width of the magnetically permeable cylinder is 8 mm,the output amplitude of the rod-shaped transducer is the largest,and when the groove width is 6 mm,the magnetic field uniformity of the rod-shaped transducer is the highest,and the amplitude difference of the transducer is small when the groove width is 8 mm and 6 mm,it is determined that the rod-shaped transducer magnetic cylinder has a groove width of 6 mm.The GMM rods of the half-wavelength transducer were sliced and slitted respectively.The effect of the structure of the GMM rod on the vibration performance of the half-wavelength transducer was studied.The results show that the slice processing is applied to the GMM rod of the low power transducer,which is beneficial to reduce the eddy current and achieve higher energy conversion.The GMM rod of the high-power transducer adopts slitting treatment,which is beneficial to ensure the integrity of the GMM rod,thereby avoiding the influence of the treatment of the GMM rod on the vibration performance of the transducer.The design of the window transducer and the rod-shaped transducer is compared.The amplitude stability of the window transducer is better.Under the same excitation voltage,the output amplitude of the window transducer is about 1.5 times the output amplitude of the rod transducer.The window transducer has small impedance,small structure and large output amplitude,which is a new direction for the development of giant magnetostrictive transducer in the future.The research in this paper has very impo rtant inspiration and reference significance for the further development and application of giant magnetostrictive power ultrasonic transducer.