Research On Ultrasonic Vibration Cylindrical Honing Technology And Its Mechanism

As a disadvantage in the traditional cutting, vibration can also impact positive influences on cutting process system under certain conditions. Ultrasonic vibration external cylindrical honing technology is a branch of ultrasonic vibration cutting technology, which is a kind of composite processing method integrating external cylindrical honing technology and ultrasonic vibration technology. It can solve the problems during the ordinary honing, such as blocking of oilstone, low processing efficiency, uncontrollable processing precision and intense labor, etc. and improve the processing dimensional accuracy and reduce the cutting force and cutting heat. In addition, it solves many difficulties that ordinary honing can not solve, especially the difficulties during the processing of slender rod and difficult-to-process materials. Currently, the researches related to ultrasonic vibration cutting technology are mainly focused on the aspects as turning, milling and flat surface grinding. Moreover, the researches on the ultrasonic vibration honing technologies are mainly concentrated on inner hole process. As a result, slender rod was nearly taken as the research object in the previous researches. Based on the systematic summarization for the large amount of domestic and oversea data and information, ultrasonic vibration external cylindrical honing technology and its mechanism is researched profoundly in this paper through the analysis on the kinematics, grinding force and grinding heat of the technology, researches on the material removal mechanism and the design of the ultrasonic vibration external cylindrical honing equipment. The contents completed in this thesis are summarized as follows:The movement between oilstone and workpiece of ultrasonic vibration external cylindrical honing is analyzed through starting from the kinematic analysis on the ordinary external cylindrical honing. And then, the expressions of the critical speed and the relative net cutting time,tc/T, are worked out. Then, Johnson-Cook material constitutive model and finite element analysis software are adopted to carry out simulated analysis for the ordinary cutting and ultrasonic vibration cutting under the same cutting parameters. Moreover, the friction reduce theory is applied to analyze and explain the results of the stimulation. Compared with ordinary cutting, the material removal mechanism of ultrasonic vibration cutting is changed greatly because of its pulse-type cutting force. Therefore, the traditional statics analysis can not be used to explain its mechanism. As a result, dynamic fracture mechanics will be adopted in this paper as a proper theory to analyze the material removal mechanism of ultrasonic vibration cutting.In consideration of the characteristics of slender rod as low rigidity, which is vulnerable to bending and deformation with its own gravity and the external cutting force, a set of new ultrasonic vibration external cylindrical honing equipment is designed to overcome some of the disadvantages of the existing equipment. This new equipment mainly consists of accessories as ultrasonic generator, transducer and ultrasonic amplitude transformer, etc.