Design And Research Of Ultrasonic Vibration Assisted ELID Grinding Devic

With the rapid development of high-end equipment manufacturing industries such as aviation,aerospace,precision instruments,and microelectronics,the application of difficult-to-machine materials has gradually become widespread in these fields.Therefore,the high-efficiency and high-quality machining of difficult-to-machine materials have brought new challenges to the current mechanical manufacturing field.The ultrasonic vibration-assisted ELID grinding technology is a precision machining method aimed at difficult-to-machine materials.This technology combines ultrasonic vibration-assisted grinding technology with ELID grinding technology and has advantages over traditional grinding processes,such as small grinding force and low grinding temperature.In this paper,the ultrasonic vibration-assisted ELID grinding device was studied,and a device was designed and optimized.The feasibility of the ultrasonic vibration-assisted ELID grinding device was verified experimentally.Specifically,the following work was conducted:(1)An integral ultrasonic vibration-assisted grinding device was designed.Based on the one-dimensional longitudinal vibration theory of slender rods,the frequency equation of the ultrasonic vibrator was derived,and the size of the vibrator was solved by using the frequency equation.The designed ultrasonic vibrator was analyzed and verified for accuracy through simulation analysis using Ansys Workbench software.(2)Multi-objective optimization design was performed on the device designed in(1).The optimization requirements of the ultrasonic vibration-assisted grinding device were analyzed,and resonance frequency,amplification factor,and node offset distance were taken as optimization objectives.The optimization of the device was completed using a surrogate model combined with a multi-objective optimization algorithm.The physical device was fabricated and tested for impedance and vibration characteristics.The experimental results showed that the designed ultrasonic vibration-assisted grinding device had excellent performance and met the design specifications.(3)An ELID cathode device was designed.The electric field distribution between the grinding wheel and the cathode was analyzed,and a mathematical model of the electric field distribution was constructed.The initial shape of the cathode was obtained using the method,and the initial cathode was iteratively corrected using Ansys Workbench software to meet the required accuracy.The structure of the flow channel of the cathode device was determined by analyzing the flow field between the grinding wheel and the cathode.(4)The ultrasonic vibration-assisted ELID grinding device was manufactured and used for the experimental machining of GH4169 superalloy.The grinding force and surface quality of the workpiece were compared and analyzed under ordinary grinding,ultrasonic grinding,ELID grinding,and ultrasonic-assisted ELID grinding processes.The feasibility of the ultrasonic vibration-assisted ELID grinding device was verified,and the results showed that the designed device could meet the expected functional and performance requirements.