Research On Ultrasonic Cutting And Polishing Technology Of Aluminum Alloy

Aluminum alloy materials are widely used in aerospace,transportation and other fields due to their excellent properties.However,the industrial production has high requirements on the processing accuracy of aluminum alloy materials.Aluminum alloy materials cannot be processed with high precision by grinding.Some researchers have proposed introducing a wiper tool in traditional turning to achieve high-quality and efficient processing of aluminum alloy materials.However,there are some problems in the process of machining,the wiper tool wears out faster and a secondary tool mark will be generated on the surface of the workpiece after cutting.This paper further proposes a method of introducing ultrasonic vibration in the feed direction during the turning process of the wiper tool.By combining the above two methods,the processing quality and processing efficiency of the workpiece will be greatly improved.In this paper,relevant researches were carried out on ultrasonic cutting and polishing processing technology of aluminum alloy materials.Firstly,the ultrasonic cutting and polishing test platform was built,and then the aluminum alloy was subjected to ultrasonic cutting and polishing processing test on the test platform.Finally,the influence of various process parameters on the processing quality is analyzed,and the process parameters are optimized.The main research contents and results of this paper are as follows:(1)According to the requirements of ultrasonic cutting and polishing processing,the ultrasonic cutting and polishing horn is designed by analytical method,and the vibration analysis is carried out by ANSYS.The error between the simulation results and the theoretical design result is 3%.The maximum amplitude of the ultrasonic cutting and polishing vibration system is 14 ? m through amplitude test.The ultrasonic cutting and polishing vibration system and the machine body are connected by designing each connecting mechanism,and the ultrasonic cutting and polishing processing test platform is built.Test the processing performance of the ultrasonic cutting and polishing vibration system,It is found that ultrasonic cutting and polishing processing is better than ordinary processing,and a higher surface quality is obtained,which meets the ultrasonic cutting and polishing processing test requirements.(2)The influence of process parameters on surface roughness,surface microhardness,cutting temperature and cutting force is studied by single factor test.The test results show that: the surface roughness of the workpiece after ultrasonic cutting and polishing increases with the increase of cutting speed,feed rate and cutting depth,and decreases with the increasing of ultrasonic amplitude;The microhardness of the workpiece surface increases firstly and then decreases with the increase of cutting speed and feed rate,and gradually decreases with the increasing of cutting depth and ultrasonic amplitude;The cutting temperature and cutting force with the increase of cutting speed,feed,cutting depth and ultrasonic amplitude,during cutting increase.(3)Aiming at the orthogonal experiment of ultrasonic cutting and polishing for aluminum alloy material is carried out,and the SNR and grey correlation analysis method are used to optimize the process parameters.The test results show that when the surface roughness is used as the process index,the optimal process parameter combination obtained by the SNR and variance analyses of the experimental results are cutting speed 50 m /min,feed rate 0.1mm/r,cutting depth 0.1mm,ultrasonic amplitude 12?m,The optimal surface quality is obtained by processing according to this parameter,and its surface roughness value Ra is 0.746?m,When the surface roughness and metal removal rate are taken as the process indexes,the optimal process parameter combination is cutting depth 0.4mm,feed rate 0.18mm/r,cutting speed 90 m /min,and ultrasonic amplitude 12?m.