Design And Process Optimization Of Rotary Ultrasonic Assisted Machining Equipment For Brittle And Rigid Materials

Brittle and rigid materials are widely used in aerospace,medical and mechanical manufacturing due to their excellent thermal stability,insulation and wear resistance.However,due to the characteristics of high hardness,high strength and brittleness,there are disadvantages such as low processing efficiency and poor processing accuracy,so an advanced processing technology and equipment is urgently needed to meet the current demand.Rotary ultrasonic assisted machining is an advanced technology to solve the above disadvantages.In order to solve the problem of hard and brittle material processing,this paper mainly does the following work:(1)Design rotary ultrasonic vibration system.According to the propagation characteristics of ultrasonic wave in rotating ultrasonic vibration system,the frequency equation of transducer was deduced by using Newton’s one dimension longitudinal vibration transmission principle and the boundary conditions between each part,and the size of transducer was obtained,and the basic size of horn and tool head was obtained by combining the empirical theory,so as to design a half wavelength exponential rotating ultrasonic vibration system.(2)Optimize the size parameters of the rotating ultrasonic vibration system.The static structure analysis,modal analysis and harmonious response analysis of the rotating ultrasonic vibration system of the above structure are carried out with the finite element software ANSYS to verify the reliability of the system design.Then,according to the variation law of the shape structure size and vibration characteristics of the system,the shape structure size of the rotating ultrasonic vibration system is optimized.(3)Build an experimental platform for rotary ultrasonic assisted machining.Based on the knowledge of mechanical design,electronic circuit and ultrasonic technology,the motor,ultrasonic generator,energy transmission parts and auxiliary connection structure of rotary ultrasonic auxiliary machining equipment are selected and designed,and the rotary ultrasonic vibration system is scientifically assembled.(4)Test the processing of brittle and rigid materials.By using the assembled rotary ultrasonic auxiliary machining equipment,taking the four important process parameters in the machining process(whether there is ultrasonic machining,spindle speed,feed speed and the difference in flexural strength of brittle and rigid materials)as the experimental factors and the axial cutting force as the evaluation index,the equihorizontal orthogonal test was carried out to obtain the optimal combination of machining parameters of brittle and rigid materials.The results were verified by the surface topography.The rotary ultrasonic vibration system designed in this paper is used to solve the problem of difficult machining of brittle and rigid materials.By reducing the cutting force to improve the machining quality and efficiency of the workpiece,it provides an effective and feasible method for high quality machining of brittle and rigid materials.