Characteristic Analysis And Test Of Ultrasonic Compound Electric Machining Vibration System

Non-traditional machining is an effective processing method to difficult-to-grinding materials and special shaped surfaces, such as superalloy, cemented carbide, diamond and so on, With the advancement of science and technology, traditional mechanical machining methods are not able to meet the manufacturing needs of gradually increase in difficult-to-grinding materials and special shaped surface parts anymore, the application of non-traditional processing methods are more widely, its research and application have become hot issues in International Manufacturing.The characteristics and application of ultrasonic machining, electrolytic machining and electrosparking are described in this paper, the research actuality, development and application in ultrasonic compound electrical processing are introduced, the technical advantages in the field of ultrasonic compound electrical processing are analyzed, the remaining problems in ultrasonic compound electrical processing are discussed:the characteristics of vibration ultrasonic system have important influence in terms of accuracy and processing efficiency of ultrasonic compound electrical processing, if the design of vibration is not reasonable, the vibration process usually does not keep stable, in order to solve this problem, the main research contents are put forward in this paper.Through the method of ANSYS and the powerful multi-physics coupling module-piezoelectric coupling analysis, the interaction relationship between the number of piezoelectric ceramics, the size of the input voltage signal, the output amplitude and natural frequency are analyzed; the vibration characteristics of vibration device, which are consist of exponential amplitude transformer and transducer(called exponential ultrasonic vibration device) and conical amplitude transformer and transducer(called conical ultrasonic vibration device) are conducted in dynamic analysis (including modal analysis and harmonic response analysis). Alternating voltage signal is exerted, the ultrasonic vibration is motivated, the voltage distribution, the stress change, the node point, the maximum stress, the vibration amplitude of end face of tool head of vibration device and other parameters are obtained in ANSYS post-processing module. The amplitude of end face of tool head of exponential and conical vibration device are measured with high frequency and precision laser micro displacement sensor, then under the same parameter conditions, the analytical value is contrast with measured value, the causes of errors between measured amplitude and analytical amplitude are discussed; the vibration characteristics of vibration device, which are consist of stepped amplitude transformer and transducer(called stepped ultrasonic vibration device) are analyzed, its cause of big error is analyzed, which is between ANSYS values and design values in the maximum stress point and displacement node, also, the necessity of transit circular arc in the cross-section mutation is analyzed; finally, the parametric optimization design of exponential vibration device is conducted, the structure of ultrasonic vibration system is optimized, which is used in the follow-up experimental study. The studies in this chapter have important theoretical guiding significance.in the optimal design of ultrasonic vibration systemThe fine synchronous ultrasonic compound electromachining system is built, which including the optimization of ultrasonic vibration device, the perfection of electrolytic and synchronous chopper power supply, the establishment of electrolytic current measurement and analysis devices, magnetic levitation stage feed device, online vibration amplitude monitoring system, precision measuring device and so on, the collaboration between the "open and broken"of pulse electrolysis power supply and ultrasonic vibration can be realized with self-developed synchronous chopper power supply, A variety of kinds of fine tool cathodes are obtained through micro discharging and multi-level micro-electrospark wire-electrode cutting, finally, the ultrasonic compound electrical processing system is established.The optimized ultrasonic vibration system is used, Low amplitude, high-frequency pulse electrolytic voltage (less than 6V) is used to conduct basic compound electric processing, on this basis, low mass fraction passivation NaNO3 with nano-diamond powder are adopted, the ultrasonic discharge-electrochemical processing tests are conducted with hard carbide materials, such as YT15, YG8 and YBD151, the conclusion that the combination of ultrasonic vibration, micro spark discharge and electrolytic action could improve the processing condition of interelectrode, the forming accuracy of workpiece and processing efficiency are further improved.Finally, a summary in finite element and experimental results of vibration device of ultrasonic processing system is obtained, further improvement and measures of system structure are proposed, the idea and prospects to establish a pleiotropic synergic online real-time regulate and control compound electromachining system are proposed.