Research On Three-Dimensional Ultrasonic Cutting Working Head

With the rapid development of aerospace, semiconductor and electronic engineering, crystalline silicon, optical glass and engineering ceramics have an ever-increasing application values in various fields. However, there are lots of challenges in the machining process of these materials, because ideal machined surfaces cannot be achieved by conventional machining approaches. The ultrasonic vibration cutting (UVC) technology has been proved to be a very promising processing method to machine these materials due to its superior performances, including decrease of the cutting force, decrease of cutting heat, improvement of the machining accuracy, decrease of the surface roughness, extension of the using life of the cutting tool.The ultrasonic vibration cutting (UVC) adds small-amplitude, high-frequency tool displacement to the cutting motion of the tool. The tool tip is driven in a small reciprocating motion. For appropriate combinations of cutting velocity, tool amplitude and frequency, the tool periodically loses contact with the chip or leaves the workpiece entirely. Domestic and foreign scholars have done a lot of researches on the ultrasonic vibration cutting technology and elliptical ultrasonic vibration cutting (EUVC) technology and made lots of very good processing effects, while the researches on three-dimensional ultrasonic vibration cutting technology is very limited, the theory is not yet mature, the kinds of cutting devices are also very less, based on this, we designed a three-dimensional ultrasonic cutting working head, the main contents are as follows:Firstly, this paper studied the basic theory of piezoelectric materials, analyzed the working principle and the basic performance of the piezoelectric stack, according to these studies we designed the corresponding structure of the piezoelectric stack which is the power source of the three-dimensional ultrasonic cutting working head.Secondly, the theories of the UVC technology have been studied deeply, combined with these theories, a three-dimensional UVC working head has been designed and the 3D model has been built, the kinematic and simulation analysis of it have been completed roughly, what’s more, the dynamics analysis which helps to extract he natural frequency and vibration mode of the working head has also been conducted by software ABAQUS, according to the analysis results, we optimize the structure to improve the first natural frequency.Finally, the finite element simulations of the metal cutting has been analyzed, we got both the three-dimensional ultrasonic vibration cutting effect and the conventional cutting effect, through compared these two cutting style’s effect with each other we can find that the three-dimensional ultrasonic vibration cutting effect is better than conventional cutting effect on decrease of the cutting force, decrease of cutting heat and so on.