Simulation Of Ultrasonic Elliptical Vibration Electrochemical Compound Machining

With the rapid development of the manufacturing industry,the quality requirements of the materials needed have increased accordingly.Traditional processing technology,processing efficiency is low,and often leads to a lot of workpiece deformation,heat,residual stress in the process of processing.The physical and mechanical properties of the workpiece do not constrain the special processing,and it is easy to process the workpiece with fine surface.At the same time,the thermal stress and residual stress are very small,so that excellent surface quality can be obtained.In this paper,a new special machining technology,ultrasonic elliptic electrochemical machining technology,which combines ECM technology with ultrasonic elliptic vibration technology,is presented.In this paper,GCR15 is taken as the research object to study the basic theory of ultrasonic elliptical vibration machining,and MATLAB software is used to simulate the ultrasonic elliptical trajectory equation.It is concluded that the shape of ultrasonic ellipse trajectory is related to the phase difference and amplitude of the input ends in two directions.When the phase difference is 0 or ?,the ultrasonic elliptical trajectory will be compressed into a straight line.At the same time,based on the removal mechanism of ultrasonic elliptical vibration machining,the motion characteristics of abrasive particles and Faraday's law,the mathematical models of ultrasonic elliptical electrochemical machining removal volume and machining depth were established.When the phase difference is ?/2,the volume of the passivated film removed by ultrasonic machining is the largest.Based on the wave equation of the amplitude transformer,a conical amplitude transformer with resonance length of 142.99 mm and amplification coefficient of 2.7,an exponential deformation amplitude transformer with resonance length of 136.93 mm and amplification coefficient of 3 and a stepped amplitude transformer with resonance length of 129.25 mm and amplification coefficient of 9 were designed,and a three-dimensional model of the ultrasonic elliptical electrochemical machining system was established by using Solid Works software.Using ANSYS Workbench finite element simulation software to carry out modal analysis on three kinds of amplitude transformer,it is concluded that the natural frequency of exponential deformation amplitude transformer is 19892 Hz,and the closest error to the theoretical value is 0.54%.There is no vibration at the joint surface of the amplitude transformer rod.The results show that the conical type with flange is closer to the theoretical value than the exponential type with flange,and the error is only 0.31%and 0.175%.The harmonic response analysis of three kinds of amplitude transducers with flanges shows that the amplitude of small end vibration of the amplitude transducers is the largest at the natural frequency of the amplitude transducers.The amplification coefficient of the amplifier is determined by the path of the large end and the small end of the amplifier.The results show that the amplification coefficients of the three kinds of amplifiers are 2.622,2.97 and 8.35,which are basically consistent with the theoretical amplification coefficients,which verifies the rationality of the design of the amplifiers.