Analysis And Experimental Research On The Mechanism Of Rotating Ultrasonic Development Machinery/Electrolytic Machining

Due to the rapid development and progress of science and technology,improving the processing accuracy and efficiency of various difficult-to-process materials has become a difficult and hot issue in domestic and foreign manufacturing industries.Special processing technology is widely used in the processing of various hard-to-machine materials(hard and brittle materials,high-temperature alloys,etc.)due to its unique technical advantages such as low cutting force(or no)and low tool(electrode)loss(or no).Ultrasonic composite machinery(grinding,milling,etc.)utilizes the ultrasonic vibration effect,which can effectively reduce the cutting force and cutting heat,and improve the processing efficiency and accuracy.In this paper,we study the mechanism of mechanical/electrolytic machining by rotating ultrasonic development,organically combine the ultrasonic effect with mechanical and electrolytic effects,and realize the high-precision and efficient processing of difficult-to-machine materials.The main research contents are:(1)Based on the theory of processing and removal of hard and brittle materials and Faraday’s law of electrolysis,based on the interaction relationship of rotating ultrasound,machinery and electrolysis,the model of removal efficiency of rotating ultrasonic forming machinery and forming electrolytic machining materials is established;from the model analysis,we can know:Increased parameters such as ultrasonic amplitude,spindle speed,electrolytic voltage,abrasive hardness/granularity can increase material removal force and improve processing efficiency;while using high-frequency pulse power supply,reduce voltage amplitude,reduce electrolyte mass fraction(reduce conductivity),Reduce the abrasive grain size can effectively improve the processing accuracy.(2)Design and build a two-dimensional rotating ultrasonic development electrolytic processing system.Design the main body of the machine tool and customize the rotating NSK high-speed spindle motor,ultrasonic vibration device,ultrasonic generator,high-frequency pulse power supply,perfect the introduction of power supply,workpiece positioning,electrolytic insulation unit,build a rotary ultrasonic electrolysis device;use the PC control interface,PLC,The drive,servo motor and stepper motor build a multi-axis linkage feed device;a combination of a radial ultrasonic vibration device and a rotary axial ultrasonic vibration device is used to build a two-dimensional ultrasonic vibration system,which can realize two-dimensional rotary ultrasonic development mechanical/electrolytic processing.(3)Optimize the design of the rotary ultrasonic vibration system.Theoretical analysis and dimensional calculation of the characteristics of piezoelectric transducer and stepped horn.The ANSYS piezoelectric analysis module was used to analyze the modal and harmonic response.When the resonance frequency was 19.8 kHz,the ultrasonic output amplitude of the stepped horn was 25.5 μm.The natural frequency decreases and the amplitude decreases.Using ANSYS to optimize the design,the output amplitude of the vibration system can reach 23 μm,and the resonance amplitude measured by the laser micro-displacement sensor is 20μm,which verifies the feasibility of the analysis and design,and the system can meet the processing requirements.(4)Carry out the basic test of copying and rotating ultrasonic machining and explore the effect of rotating ultrasonic machining parameters on machining accuracy and efficiency.The test results show that:within a certain range,with the increase of ultrasonic amplitude,the increase of spindle speed,electrolysis Increasing the voltage amplitude can effectively improve the processing efficiency,but excessively high speed of the tool electrode can easily cause heating and burning.Increased voltage amplitude can affect the machining accuracy;on this basis,plane and groove rotation ultrasound Exhibit into mechanical/electrolytic machining test to get good machining accuracy and efficiency.Finally,the optimized parameters were selected,and the ceramic particle-reinforced metal matrix composite material was subjected to rotary ultrasonic flattening plane machining and two-dimensional rotary ultrasonic electrolysis flattening groove cutting processing test.The advantages of electrolysis technology.