Design And Experiment Of Rotary Ultrasonic Composite Electrochemical Machining System For Hard And Tough Materials

Due to the development of science and technology towards high-precision and miniaturized products,and due to the large number of hard,tough and other difficult materials,special processing technology has become a key research direction of modern manufacturing.Ultrasonic composite electrochemical machining is not affected by hardness and mechanical properties of materials,and is an effective machining method for hard,tough and other difficult materials.The rotating ultrasonic composite electrochemical machining technology can further improve the machining efficiency,precision and quality.The design,analysis and experimental research of rotary ultrasonic compound electrochemical machining system are carried out in this paper.The main contents of this paper are as follows:Firstly,the characteristics and applications of copying ultrasonic machining,electrolytic and discharge machining,ultrasonic composite/assisted machining,rotary ultrasonic machining and multi-dimensional rotary ultrasonic machining were comprehensively discussed,and their research status at home and abroad was analyzed.On this basis,the"rotating ultrasonic composite electrochemical machining method" was further proposed,and its technical characteristics and advantages were expounded.The mechanism of rotating ultrasonic compound electrochemical machining was analyzed,and the displacement of the table under ultrasonic vibration excitation was analyzed and solved according to vibration dynamics theory.Based on the brittle material removal theory,the material removal rate model of rotating ultrasonic machining was established.Based on Faraday’s electrolytic law,the material removal rate model of ultrasonic composite electrochemical machining was established,and the influence law of parameters on the material removal rate of rotating ultrasonic composite electrochemical machining was analyzed and discussed.The relationship between rotating ultrasonic and electrolysis was studied,the material removal rate model of rotating ultrasonic composite electrochemical machining was derived,and the interaction between various energy fields was analyzed.The whole and each component of the rotating ultrasonic electrochemical machining system were analyzed and designed,including the rotating ultrasonic spindle,piezoelectric transducer,ultrasonic amplitude transformer,tool electrode and multi-dimensional ultrasonic vibration device,etc.,to construct the rotating ultrasonic electrochemical machining test platform required by the test requirements.The piezoelectric analysis function of ANSYS Workbench was used to analyze the dynamic characteristics of piezoelectric ceramic plate group,piezoelectric transducer,exponential deformation amplitude and stepped amplitude transformer.The relationship between the number of piezoelectric ceramic plates and the loading voltage,the output amplitude and the natural frequency of the device was studied.The displacement node,stress maximum point and other parameters of exponential and stepped ultrasonic vibration device were analyzed after processing on Workbench,and the rationality of calculation analysis was checked compared with the theoretical calculation values.The exponential deformation amplitude rod is optimized to improve the output amplitude of the ultrasonic vibration device.The output amplitude of the optimized ultrasonic vibration device is tested and compared with the ANSYS analysis results to ensure that the designed ultrasonic vibration device meets the technical requirements of the rotary ultrasonic composite electrochemical machining system.Carry out parameter detection design of rotary ultrasonic compound electrochemical machining system,including ultrasonic amplitude detection,electrical signal detection,electrolyte parameter detection and machining depth detection,make tool electrodes of different shapes,improve the rotary ultrasonic compound electrochemical machining system,design machining comparison test scheme.The comparison test of different metal and nonmetal hard and tough materials by copying ultrasonic machining shows that hard and tough materials can be processed effectively by ultrasonic machining,but the processing efficiency of metal materials is low.The comparative tests on piezoelectric ceramics(PZT),high-silicon aluminum alloy and high speed steel(W18Cr4V)by one-dimensional rotating ultrasonic composite electrochemical machining show that the rotating ultrasonic composite electrochemical machining can improve the machining efficiency,and increasing the ultrasonic amplitude and electrolytic voltage can improve the machining efficiency,but the higher the voltage,the more serious the stray corrosion,the lower the machining quality.A comparative test of bearing steel(Cr15)and metal-reinforced ceramics(Al)was carried out by two-dimensional rotating ultrasonic compound electrochemical machining.The results show that compared with one-dimensional ultrasonic,two-dimensional ultrasonic can process more fine surfaces and improve the machining efficiency at the same time.