Design And Test Of Rotary Ultrasonic Compound/Auxiliary Electrolytic-discharge Generating Machining System

With the progress of science and technology and the rapid development of manufacturing technology,higher requirements are put forward for material properties and manufacturing quality of parts.With the increasing application of high-strength steel,composite materials and various complex structural parts,there are usually some problems in traditional machining,such as difficult machining,low machining efficiency,high tool wear and so on.Special machining and its compound machining technology can carry out efficient and high precision machining of all kinds of difficult-to-machining material parts through special energy such as discharge,electrolysis,ultrasound,laser and so on.In this paper,rotating ultrasound,mechanical,electrolysis,discharge and other energy fields are organically integrated to study the rotary ultrasonic composite/auxiliary electrolysis-discharge machining technology.The main research contents are as follows:(1)Analyze the realization mode and mechanism of rotary ultrasonic compound/auxiliary electrolytic discharge generating machining;on this basis,design the machining system and Z-axis servo feed mechanism,which can control Z-axis feed;design rotating ultrasonic vibration device,design ultrasonic vibration system and its power supply mode,theoretically design the size of ultrasonic vibration system,design radial ultrasonic device,realize two-dimensional ultrasonic vibration.The electrolysis-discharge device is designed;the multi-axis feed mechanism is designed;the rotary ultrasonic compound/auxiliary electrolytic-discharge generating machining system is constructed,which can realize the fouraxis generating machining of X,Y,Z and C;the parameter detection device is designed to detect the radial ultrasonic amplitude and design the conductivity compensation scheme.(2)The structural dynamics of the theoretically designed ultrasonic transducer,horn and ultrasonic vibration system are analyzed by using ANSYS software.when the resonance frequency is 19.8kHz,the maximum output amplitude of the system theory is 40μm.The ultrasonic vibration system is optimized,and the optimization results show that the maximum output amplitude is 43μm when the resonance frequency is 19.8kHz,which verifies the advantage of ANSYS in optimizing the size parameters of the vibration system.35μm is measured with laser micro-displacement sensor to meet the requirements of ultrasonic composite/auxiliary electrolysis-discharge machining.(3)A test scheme is designed to carry out grinding,rotary ultrasonic and composite/auxiliary electrolytic-discharge generating machining of high silicon aluminum alloy,and it is proved that the compound/auxiliary electrolytic-discharge method can effectively improve the machining efficiency.Cemented carbide rotary ultrasonic composite/auxiliary electrolytic-discharge generating machining experiments under different voltages were designed to explore the effect of voltage on compound/auxiliary electrolytic-discharge generating machining.It is found that the current stray corrosion is serious when the voltage reaches 8V,and 2V-6V is the ideal processing voltage.The experiments of side generating machining of high silicon aluminum alloy were carried out to verify the machining advantages of rotary ultrasonic compound/auxiliary electrolytic discharge generating machining,and the experiments of one-dimensional and two-dimensional rotary ultrasonic composite/auxiliary electrolytic discharge generating machining of aluminum-based silicon carbide were carried out.it is verified that the two-dimensional ultrasonic compound/auxiliary electrolytic discharge generating machining has higher stability and can effectively improve the machining efficiency.Through the experiments of one-dimensional and two-dimensional rotary ultrasonic composite/auxiliary electrolytic-discharge generating machining of metal-based ceramic reinforced materials,it is found that the surface roughness Ra is reduced from 4.8μm to 3.4μm by two-dimensional rotary ultrasonic composite/auxiliary electrolytic-discharge generating process,which verifies the technical advantages of two-dimensional composite/auxiliary electrolytic-discharge generating machining.