Design And Analysis Of Auxiliary Machining Device With Single Excitation Three-dimensional Ultrasonic Vibration

Vibration-assisted machining has become an indispensable technology in precision and special machining with the advantages of low average cutting force,high machining efficiency,and good surface machining quality.It can be used for composite materials,hard and brittle materials and other difficult-to-process materials,such as ceramics and glass.,Cemented carbide,etc.Among them,three-dimensional vibration-assisted processing is considered to be the most promising processing method,but domestic and foreign research focuses on multi-excitation devices.The special structure coupling becomes three-dimensional vibration,which requires high coordination between multiple excitation sources.The device has a complicated structure and a large volume.Therefore,this paper designs a small,simple structure single excitation three-dimensional ultrasonic vibration auxiliary processing device.The specific content of the paper is as follows:(1)Based on the ultrasonic oblique incidence theory,this paper analyzes the compound vibration mechanism of the chute structure,and proposes a horn with a chute structure.The horn can generate X,Y,and Z directions under a single excitation.The simple harmonic vibration of the same frequency is the output of elliptical vibration trajectory in space,and a set of single excitation three-dimensional ultrasonic vibration auxiliary processing device is designed.(2)The modal analysis of the horn is carried out,and its natural frequency and mode shape are obtained.Through the node path analysis,it is determined that the second-order mode meets the requirements.Subsequently,the vibration characteristics of the output end of the horn were obtained through instantaneous dynamic analysis,which verified that the vibration track of the output end of the horn in space was ellipse-like.Finally,the angle,number,length,and width of the chute were explored through the controlled variable method.Regarding the influence law of chute mode conversion,the chute structure of the horn is optimized.The simulation results show that the chute type horn meets expectations and can be used in a single-excitation three-dimensional ultrasonic vibration auxiliary processing device.(3)An experimental test system for a single excitation three-dimensional ultrasonic vibration auxiliary processing device was built.First,the natural frequency of the chute-type horn was tested,and the three directions of the horn X,Y,and Z were measured under resonance.Through the analysis of experimental data,the magnification factor of the horn and the spatial vibration trajectory are obtained.The experiment proves that the single excitation chute type horn can output the spatial elliptical vibration trajectory,and the single excitation three-dimensional vibration auxiliary processing device meets the design requirements.