Difficult-to-machine Materials/deformed Surface Ultrasonic Assisted The Pure Electric Processing System Optimization And Application Research

In this paper, the concept of micro-machining and its technical characteristics are introduced. Meanwhile, the processes used in combined-machining and micro non-traditional machining technologies are outlined as well. Furthermore, the importance of micro-machining about USM (Ultrasonic Machining) and ECM (Electrochemical Machining) is analyzed and emphasized. Based on these theories, the combined micro-machining technology of USM and ECM is proposed.What’s more, the mechanism system, equipment of USM and ECM are summarized. Accordingly, the process requirements of the combined technology are suggested. And then, a discussion about the necessity, feasibility and advantage of combined micro-machining of USM and ECM is given.To make research on the process system, the key point is about the dynamics study of amplitude transformer horn. In the process of modal analysis, get their inherent frequency; In the process of harmonic response analysis, get the response accord with their inherent frequency and amplification coefficient. After comparing with the parameter calculated, they are almost the same with each other. It sets up a good foundation for the use of amplitude transformer horn. In the process of modal analysis, get the inherent frequency near15KHz;In the process of harmonic response analysis of the system, get the difference, and adjust some data to get the perfect system.IBesides, the manufacturing process of micro cathodes is a key for the combined micro-machining of USM and ECM. Firstly, make a surface on the basis of VC. Combined with the system we get and electrical discharge machining is proposed to make cathodes that will be used in later tests, including the "copy adding translate","multi-axle linking feeds". In these means, experimental cathodes with different cross sections could be made and the general means are summarized.During the experiments, the solo ultrasonic machining experiments are carried out on piezoelectric ceramics, silicon sheet and cemented carbide. And then micro-machining of USM and ECM is done on the cemented carbides. So detailed analysis is made on the machining precision, abrasion wear of the cathode and efficiency, including the influence of electrolyte, electrical parameters (voltage, pulse parameter), amplitude, frequency, contact pressure and abrading granularity. The possibility, feasibility and advantages of the combined micro-machining technology used in machining micro elements is confirmed, all of which provide the basic condition in the application of combined micro-machining of USM and ECM.In the end, the technology characteristics of this micro-machining is analyzed and summarized.What’s more, process problems, disadvantages and its improvement methods are also suggested. So further study should be put forward.