Structural Design And Simulation Analysis Of Special-shaped Surface Honeycomb Composite For Ultrasonic Processing System

Honeycomb composite materials due to high specific strength,specific stiffness,light weight,strong corrosion resistance,self-extinguishing,excellent insulation and environmental resistance and other advantages are widely used in aerospace and other fields,with the rapid development of aerospace,new energy and other fields of top equipment technology,composite materials large size,special-shaped,curved and other special shape of the overall forming technology requirements are more and more demanding,ultrasonic processing technology for the processing of honeycomb composite materials has unique advantages,and is widely used in the processing of honeycomb composite materials,As important components of ultrasonic cutting processing system,ultrasonic luffing rods and machining tools seriously affect the processing efficiency,processing quality and stability of composite materials.This paper starts from the processing of special-shaped surface honeycomb composite materials,which belongs to the finishing process,and the commonly used machining tool is a disc cutter cutting tool.In the actual machining process,the traditional luffing rod is difficult to achieve the ideal machining effect,and the tool is used as an execution tool in the ultrasonic machining system,and its structural size and shape directly affect the processing quality and accuracy.The main research contents of this paper are as follows:(1)There is a stress concentration for the sudden change in the junction of the section of the stepped luffing rod,which is not suitable for working in high amplitude.Taking into account the shape factor and magnification coefficient,the stepped luffing rod of the exponential transition section,cone transition section and catenary transition section was designed,the parameter equation of the amplitude rod was established through the wave equation,the resonant length,magnification and node position of the luffing rod were calculated,and a parametric model was established.(2)With the help of ANSYS Workbench software,the three stepped composite luffing rods of the design were simulated and analyzed,the correctness of the theoretical model of the luffing rod was verified,the luffing rod was optimized by adjusting the length of the luffing rod,and the optimized luffing rod was simulated and analyzed,and the stepped luffing rod of the exponential transition section was determined as the design luffing rod by comparing the performance parameters of the three stepped composite luffing.(3)The structure of the transducer is designed,and the structural design of the disc tool is carried out on the basis of the stepped luffing rod of the exponential transition section,which is connected to the luffing rod,the influence of tool thickness,tool diameter,tool wedge angle and tool back angle on the processing system is studied,the structural parameters of the tool are determined,and the lateral vibration of the tool is reduced by grooving.(4)The ultrasonic machining disc tool motion analysis was carried out,the ultrasonic machining force-thermal coupling finite element model of honeycomb composite material was established,and the effects of tool diameter,tool wedge angle and tool back angle on cutting force and cutting temperature were studied.