Research On The Design And Application Of Precision Ultrasonic And Composite Electrochemical Machining Of Difficult-to-machine Parts

With the development of science and technology,high-tech products have become increasingly sophisticated and miniaturized.They have also developed in the direction of difficult-to-machine materials and profiled surfaces.Therefore,it has become a technical problem and an important research hotspot for mechanical manufacturing.Traditional machining methods(turning,milling,grinding,planing,etc.)have been unable to meet the processing requirements of difficult-to-machine parts,but have used non-mechanical energy(electrical,optical,thermal,acoustic,chemical,etc.)to perform special processing.The technology(discharge,electrolysis,ultrasound,laser processing,etc.)has the processing characteristics of"soft-on-yellow" and "copy-type forming" and is very suitable for the precision machining of such parts.This article studies the ultrasonic,ultrasonic composite mechanical and ultrasonic compound electrolysis precision machining technology for difficult-to-machine parts,and conducts related technical process design and tests,seeking an effective method for manufacturing such components.This paper analyzes the research,development and application of ultrasound and its composite processing technologies both at home and abroad.Based on the process features and technical advantages of precision ultrasonic and its compound electrolytic processing technologies,it designs,according to the requirements of ultrasonic vibration theory and ultrasonic machining technology.A digital ultrasonic generator with a reasonable frequency range,frequency automatic feedback and tracking,designing and developing piezoelectric transducers and amplitude expansion rods(amplifiers)for precision ultrasonic and ultrasonic machining.Using ANSYS finite element analysis software,using a powerful multi-physics coupling module-piezoelectric coupling analysis module to analyze the dynamic characteristics of the piezoelectric transducer;dynamics of the ultrasonic vibration system using exponential and stepped horn in the characteristic analysis,the parameters such as the displacement node,the maximum stress point,and the amplitude of the tool electrode end face of the vibration system are obtained from the post-processing of ANSYS.The parameter analysis value is compared with the theoretical calculation value,which proves that the ultrasonic vibration system of the exponential variable amplitude bar has the highest degree of coincidence.The exponential ultrasonic vibration system is optimized,and the ultrasonic vibration device is developed based on the optimized data.The ultrasonic vibration sensor is used to measure the amplitude of the electrode end face of the ultrasonic vibration system,and compared with the finite element analysis results,the developed ultrasonic vibration system can be verified.To meet the technical requirements of precision ultrasonic and composite electrolytic processing.Construct and improve precision ultrasonic and ultrasonic composite electrolytic processing systems,produce a variety of cross-section tool electrodes required for testing,conduct precision ultrasonic and multiple-electrolytic processing of a variety of micro-structres,and perform hard and crisp PZT ceramic materials ultrasonic machining test to verify the working reliability of the processing system,and to explore the effect of material mechanical characteristics on the material removal efficiency;to conduct basic tests of precision ultrasonic composite electrolytic machining,to obtain the effect of different processing parameters on the material removal rate,and to verify pulse electrolysis.The effectiveness of the model of material removal efficiency was studied.Through single-ultrasonic and ultrasonic composite electrolysis machining contrast tests,the relationship between the material removal rate and each energy interaction between ultrasonic processing,ultrasonic composite electrolysis processing,and ultrasonic composite pulse electrolysis processing was discussed.The comparison between the mechanical drilling of PZT ceramics and stainless steel materials and the addition of rotary ultrasonic testing has proved that the processing efficiency is significantly improved after additional rotary ultrasonication,and increases with the increase of the ultrasonic amplitude,and ultrasonic and ultrasonic composite electrolytic processing are used.Methods the precision machining of piezoelectric devices was performed.The machining efficiency,accuracy,and qualification rate were significantly higher than those of mechanical drilling,and the workpieces were successfully applied to verify the technical advantages of this combined ultrasonic machining method.This paper summarizes the development and experimental research of ultrasonic composite electrolytic machining vibration system,and puts forward the applicable conditions,existing problems and perfect measures of the existing processing system and removal efficiency model.