Research And Application Of Multi-energy Action Mechanism And Optimal Control Of Ultrasonic Composite Electric Machining

With the rapid development of manufacturing industry,modern industrial products have developed toward miniaturization and high precision.For hard and brittle materials,ultrasonic machining technology has the technical advantages of high efficiency and good precision,however,for materials with high hardness and high toughness(low brittleness),the ultrasonic machining efficiency is significantly reduced and the tool head is susceptible to wear,ultrasonic processing and electro-machining organic compound ultrasonic composite electro-machining technology has advantages of compounding,and can perform high-precision and high-efficiency processing of parts with high hardness and toughness.However,the ultrasonic composite electrical machining process has many influencing parameters and complex changes,and the stability of the processing process is often difficult to maintain,in order to solve this problem,the multi-energy action mechanism and process control of ultrasound composite electrical machining process are studied and tested.This article outlines the principle and processing characteristics of ultrasonic machining,EDM machining and electrolytic machining,analyzes the research status of ultrasonic composite electric machining technology at home and abroad,discusses the detection methods and control techniques of its main processing parameters,and formulates parameters detection and control program;Analyze ultrasonic vibration parameters,electrical machining parameters,working fluid and other parameters,quantitatively analyze the influence law of its processing efficiency and precision,and establish a composite electrical machining efficiency model;According to the characteristics of process parameters change,effective control measures and strategies are proposed to adjust the matching relationship between ultrasonic vibration energy and electric processing energy on-line and in real-time,maintain the continuous stability and optimization of the machining process,effectively improve the machining efficiency and ensure the machining accuracy.Construct and perfect ultrasound composite electrical processing system,including:ultrasonic vibration device,electric processing device,synchronous chopping wave power supply,magnetic levitation table,etc;A variety of high-precision,high-speed sensors,data storage oscilloscopes,data acquisition cards,I/O interfaces,and control devices are used to design,build,and improve composite electrical machining parameter detection and control systems,the on-line detection of parameters such as ultrasonic amplitude,output voltage of the electro-processing pulse power supply,current between the electric machining electrodes,etc,and the analog signals detected by each parameter were converted into digital signals that can be recognized by the computer through the PCI-1706U data acquisition card;STM32 control the digital potentiometer(replace the original manual mechanical potentiometer)to control the ultrasonic power supply;Through the control software and output interface,real-time control of ultrasonic amplitude(digital potentiometer adjustment of the ultrasonic power supply excitation voltage),electrical processing voltage amplitude and power threshold range.Using Visual C++6.0 development and design of ultrasonic composite electrical machining detection and control system software to achieve processing conditions set and processing parameters acquisition?processing?display and storage functions.Design and manufacture a variety of micro-tool electrode with truncated end face,using cemented carbide YT15 and YG8?FRP?stainless steel and other materials,using the developed ultrasonic composite electro-processing system with parameter detection and control functions to conduct ultrasonic composite electro-machining test Study and analyze the influence of main parameters on processing efficiency and machining accuracy.Using a single ultrasonic machining test,manual adjustment and system software adaptive control adjustment stability and processing efficiency comparison test;The ultrasonic composite electrical machining parameter test was conducted.The results showed that the ultrasonic composite electrical processing system for parameter detection and control was stable,the machining accuracy was stable,and the processing efficiency was significantly improved.