Research On Metal Foil Consolidation Vibration System Based On Piezoelectric Ultrasonic

Metal ultrasonic additive manufacturing,also known as ultrasonic metal consolidation technology,is widely used in the fields of biological science and national defense aerospace due to its advantages of low forming temperature,energy saving,high efficiency and environmental protection.In the process of metal foil consolidation,the ultrasonic consolidation vibration system is the main factor affecting the consolidation effect.The traditional ultrasonic consolidation vibration system is driven by a single transducer on one side,which has the characteristics of small amplitude and unstable continuous consolidation.In order to improve the output amplitude of the consolidation vibration system,a double-head ultrasonic consolidation vibration system is proposed.Combined with the principle of ultrasonic vibration,the structural parameter design,finite element simulation analysis,structural parameter optimization and amplitude test experiment of the system are studied.The main research contents are as follows.Firstly,the structural design of the double-head ultrasonic consolidation vibration system was carried out.By studied and analyzed the key performance parameters of the transducer and the working principle and function of the ultrasonic horn,the selection of the transducer and the ultrasonic horn was completed.Based on the longitudinal vibration theory and the design theory of conical composite horn,the structural size design of transducer and ultrasonic horn was carried out.According to the actual engineering experience and assembly requirements,the selection and structural size of the consolidation tool head were determined.Secondly,based on the dynamic principle,the finite element analysis and structural parameter optimization of the double-head ultrasonic consolidation vibration system were carried out.Based on the ANSYS Workbench simulation platform,the modal analysis of the double-head ultrasonic consolidation vibration system was carried out to obtain the vibration mode near the target resonance frequency of 20 kHz.Based on Design Exploration,the structural parameters of the ultrasonic horn were optimized,the fitting of the response surface curve was completed,the influence of the length of the ultrasonic horn on the resonant frequency was obtained,and the optimal structural size near 20 kHz in the longitudinal vibration state was determined.Thirdly,based on the equivalent four-terminal network method,the modeling and simulation of the double-head ultrasonic consolidation vibration system were completed.The equivalent four-terminal network matrix of the variable cross-section bar and the composite bar was established,and the no-load force analysis of the double-head ultrasonic consolidation vibration system was carried out.Based on Newton’s laws of motion,the consolidation vibration system was abstracted as a dynamic model of mass-stiffness-damping,and the equivalent physical parameters of the consolidation vibration system were solved.Based on Matlab/Simulink,the modeling and simulation of double-head ultrasonic consolidation vibration system were completed.Finally,the experimental prototype of ultrasonic consolidation vibration system with double vibrating head was made,and the experimental platform was built to test the amplitude,and the relationship between output amplitude and excitation voltage was explored.The experimental results show that the output amplitude is linearly correlated with the excitation voltage,and the maximum output amplitude of the consolidated vibration system can reach 34.4 μm,which achieves the design goal of this thesis.The structural vibration mode of the double-head ultrasonic consolidation vibration system proposed in this thesis is correct,which effectively improves the output amplitude of the system and has positive significance for the improvement of the consolidation effect.It provides a new reference for the development of the subsequent ultrasonic consolidation vibration system and further promotes the application of ultrasonic consolidation technology in related fields.