Study On The Surface Quality Of Alumina Ceramics Cut By Inner Diameter Saw Assisted By Two-dimensional Ultrasound

Inner diameter machining is the main method for slicing small and medium-sized hard and brittle materials.Although multi-station inner diameter slicing machines and inner diameter blade tensioning technology are increasingly sophisticated,the surface quality of the slices obtained by inner diameter slicing machines is poor,and subsequent precision machining steps are cumbersome.These issues have not been resolved,which also limits the development and application of inner diameter machining.Ultrasonic machining can improve machining quality and reduce cutting forces.One-dimensional ultrasonic-assisted inner diameter machining improves slice surface quality,but there are still issues such as low efficiency and uncontrollable surface quality,and more suitable methods need to be explored to further improve slice surface quality.Existing research has shown that two-dimensional ultrasonic machining has separation characteristics and machining accuracy superior to one-dimensional ultrasonic machining.Therefore,this article proposes a method that combines two-dimensional ultrasonic machining with inner diameter machining to solve the problems of onedimensional ultrasonic-assisted inner diameter machining mentioned above.The primary focus of this article encompasses the following research endeavors:(1)Design of a two-dimensional ultrasonic transducer structure.Based on the traditional longitudinal transducer design method and the Timoshenko equation for the straight beam bending array,the intersection points of longitudinal and bending resonances is obtained by solving the frequency equations for longitudinal and bending vibrations,which is used to determine the length of the two-dimensional ultrasonic transducer.After inserting two piezoelectric ceramics,the length of the twodimensional ultrasonic transducer is corrected using a length correction formula.A parameterized model of the two-dimensional ultrasonic transducer structure is established,and finite element software is used to perform modal analysis,harmonic response analysis,and optimization analysis to complete the design of the twodimensional ultrasonic transducer structure.(2)Investigation of cutting forces in two-dimensional ultrasonic-assisted inner circular machining.A test platform for two-dimensional ultrasonic-assisted inner circular sawing is established,and orthogonal experiments are designed and conducted.The torque signals measured by six-axis force sensors in the experiments are decoupled to obtain cutting force data.The data is then processed for denoising and envelope analysis to establish a cutting force formula for two-dimensional ultrasonic-assisted inner circular sawing.The significance test is conducted using the F-test method to obtain the influence laws of spindle speed,feed rate,abrasive particle size,blade thickness,and blade inner diameter on cutting forces.(3)Surface quality study of two-dimensional ultrasonic-assisted alumina ceramic slicing.The removal mechanism of hard and brittle materials in two-dimensional ultrasonic-assisted inner circular sawing is investigated to determine the processing and testing schemes for alumina ceramic slicing.The surface quality of alumina ceramic slices obtained by two-dimensional ultrasonic-assisted inner circular sawing and traditional inner circular machining is compared to verify the feasibility of the former method.The influence of processing parameters on the surface quality of alumina ceramic slices is explored based on roughness parameters of the slice surface.Due to the high precision and efficiency achievable with two-dimensional ultrasonic machining,as well as its ability to improve the life of inner cutting tools,this paper combines two-dimensional ultrasonic machining with inner diameter cutting.A formula for the cutting force of two-dimensional ultrasonic-assisted inner diameter sawing was established,and the influence of machining parameters on cutting force was explored.The surface quality of the ceramic slices obtained by two-dimensional ultrasonic-assisted inner diameter cutting was compared with that obtained by traditional inner diameter cutting,confirming the superiority of two-dimensional ultrasonic-assisted machining.This method utilizes the coupling effect of the diamond abrasive particles attached to the two-dimensional ultrasonic transducer and the inner cutting tool to form a controllable ultrasonic interference pattern on the workpiece surface,achieving high-precision machining of aluminum oxide ceramics.