基于FEM和DOE分析的超声切刀结构设计与振动特性研究  

Structural Design and Vibration Characteristics of Ultrasonic Cutter Based on FEM and DOE Analysis

作　　者：李永亮 杜彦斌[1] 梁强 杨承志 LI Yongliang;DU Yanbin;LIANG Qiang;YANG Chengzhi(Chongqing Key Laboratory of Green Design and Manufacturing of Intelligent Equipment,Chongqing Technology and Business University,Chongqing 400067,China;Chongqing Linghuan Electromechanical Equipment Co.,Ltd.,Chongqing 401320,China)

机构地区：[1]重庆工商大学智能装备绿色设计与制造重庆市重点实验室,重庆400067 [2]重庆凌焕机电设备有限公司,重庆401320

出　　处：《重庆工商大学学报（自然科学版）》2024年第4期17-25,共9页Journal of Chongqing Technology and Business University:Natural Science Edition

基　　金：重庆市自然科学基金(CSTC2020JCYJ-MSXMX0276);重庆市教委科学技术项目(KJQN201900827)。

摘　　要：目的针对工程实践中超声切刀尺寸难以解析计算且有特定结构尺寸要求的超声切刀难以设计等问题,建立了装夹式组合超声切刀结构优化及振动特性的高效设计、分析方法。方法依托某工程实践超声切刀设计要求,以结构尺寸参数化的阶梯形变幅杆和固定渐变刀刃体装夹设计成组合式超声切刀,通过对变幅杆单一结构尺寸因素对组合超声切刀有限元模态固有纵振频率、输出形变大小等振动特性的影响分析,合理选取结构尺寸取值范围,构建了四因素两水平的全因子仿真实验,进行了多结构因素交互影响分析,建立了显著因素的谐振频率回归方程,并基于此以简谐共振频率为目标,优化设计了28 kHz装夹式超声切刀。结果通过有限元模态分析、谐响应分析验证了优化设计的超声切刀在固有纵振、谐振频率与目标设计的一致性,且仿真输出振幅满足超声切割振幅要求,仿真最大等效应力远小于材料的安全许用屈服强度;通过数控加工、阻抗测试验证了实验测试频率与设计、仿真频率的一致性,且阻抗值满足设计要求;将超声切刀安装至切割系统中进行加工实验,通过与普通刀具、激光等工艺加工手段进行对比,设计切刀输出频率与振幅稳定,切割质量好,效率高。结论研究结果表明:采用的超声切刀结构设计、仿真、分析等方法对有特定尺寸要求的复杂切刀设计、优化及工程应用具有很好的指导意义。Objective In view of the problems that the ultrasonic cutter size is difficult to be calculated analytically and the ultrasonic cutter with specific structural size requirements is difficult to be designed in engineering practice,an efficient design and analysis method for the structural optimization and vibration characteristics of the clamped combination ultrasonic cutters was established.Methods The method was based on the design requirements of an engineering practice ultrasonic cutter,and a combination ultrasonic cutter was designed with a stepped variable amplitude horn and a fixed gradient blade body clamped by the structural dimension parameterization.The study analyzed the influence of the single structural size factor of the ultrasonic horn on the vibration characteristics of the finite element modal inherent longitudinal vibration frequency and output deformation size of the combined ultrasonic cutter,reasonably selected the range of structural size values,constructed a four-factor,two-level full-factor simulation experiment,conducted a multi-structural factor interaction analysis,and established a resonant frequency regression equation with significant factors.Based on this,with the simple harmonic resonant frequency as the target,the 28 kHz clamped ultrasonic cutter was designed and optimized.Results Through finite element modal analysis and harmonic response analysis,the consistency of the optimized ultrasonic cutter in the inherent longitudinal vibration and resonant frequency with the target design was verified.The simulation output amplitude met the ultrasonic cutting amplitude requirements,and the simulation maximum equivalent force was much smaller than the safe allowable yield strength of the material.The consistency of the experimental test frequency with the design and simulation frequency was verified through CNC machining and impedance testing,and the impedance value met the design requirements.The ultrasonic cutter was installed into the cutting system for processing experiments,and throu

关 键 词：超声切刀 FEM分析 析因交互影响分析 振动特性 

分 类 号：TB559[理学—物理]