Mechanism Analysis And Experimental Study Of Rotary Ultrasonic Ultrasonic Milling

Material is one of the important pillars of high and new technology,and is the important material basis for the development of economy and industries.With the continuous renewal and development of high-tech fields,higher performance requirements are put forward for materials,and a variety of new materials with excellent physical,chemical and mechanical properties are constantly emerging.At the same time,because of the special structure and excellent performance of these new materials,the traditional processing methods can not meet their processing requirements.Compared with special machining methods such as EDM and laser machining,ultrasonic machining is the solution to this difficulty.Rotating ultrasonic milling changes the relative motion state between the tool and the workpiece,which can significantly reduce the cutting force and cutting heat compared with traditional milling.At the same time can get a higher workpiece surface quality and processing accuracy,chip easy to deal with,high tool durability,so that the machining stability and other advantages.The research of ultrasonic milling technology is less and the unique advantages of milling technology,so the research of ultrasonic milling is very urgent,and has a great significance of scientific and technological development.In this paper,on the theoretical analysis,combination of TC4 and CFRP structure performance of two different materials,such as the different analysis of the material removal mechanism of ultrasonic milling,ultrasonic milling milling force,tool wear and cutting heat is analyzed,and establish the kinematics model of ultrasonic milling,milling force mathematical model and make a comprehensive analysis of the source of the milling force It is concluded that ultrasonic milling makes the thickness and motion Angle of the metal layer change periodically.The unique advantages of this processing technology are analyzed theoretically.In the simulation analysis,ABAQUS software was used in this paper to carry out simulation,and it was found that the cutting temperature of ultrasonic milling was significantly lower than that of traditional milling,and the milling force was significantly reduced after ultrasonic was added.At the same time,the simulation results show that the cutting temperature and milling force increase with the increase of cutting depth.The cutting temperature and milling force change obviously when the cutting depth is between 0.6mm and 0.8.In the experimental research,this paper uses the combination of non-contact power supply ultrasonic milling auxiliary device and CNC machining center to carry out processing tests on TC4 and CFRP carbon fiber composites respectively.The optimized effect of rotary ultrasonic machining was analyzed by taking the surface topography of the milling surface,cutting edge and tool wear,surface roughness Ra and milling force as evaluation parameters.The test results show that ultrasonic milling has great advantages.The ultrasonic frequency in the test was as high as 50 k Hz.The removal mechanism of the two materials was analyzed by comparing the ultrasonic milling with the traditional milling test to further analyze the ultrasonic milling mechanism.Taking TC4 as the machining object,the milling force of ultrasonic milling is reduced by 48%compared with that of traditional milling in the direction of X axis.The milling force of ultrasonic milling is affected by X axis,Y axis and Z axis in descending order,and the surface roughness is increased by 13%.Taking CFRP T300 as the research object,the milling force of CFRP T300 is reduced by 23% compared with that of conventional milling in the direction of X axis,and the defects of CFRP composites are significantly reduced by ultrasonic milling.Using TC4 as the research object,the single factor experiment shows that the cutting force increases with the increase of feed speed and cutting depth feed speed within a certain range.When the cooling mode is changed,the machining quality of ultrasonic milling TC4 is from good to bad,and the milling force is from small to large in the following order: water-based cutting fluid>Water >Air cooled >Without cooling;The machining effects of ultrasonic milling with CFRP T300 as the research object are as follows: water-based cutting fluid >Air cooled >Water >No cooling,cutting force from small to large order as: water-based cutting fluid >Water >Air cooled>Without cooling;Compared with traditional milling,rotary ultrasonic machining can obviously reduce the edge breaking effect of inlet and improve the quality of hole.Through the tool wear test,it is concluded that ultrasonic milling can prolong the tool service life by 40%.