大振幅超声振动辅助高速干切装置设计开发与性能测试  

Design and development of a large-amplitude ultrasonic vibrationassisted high-speed dry cutting device and its performance tests

作　　者：黄雪峰 曹华军[1] 张金 宋阳[1] 康信禛 HUANG Xuefeng;CAO Huajun;ZHANG Jin;SONG Yang;KANG Xinzhen(College of Mechanical and Vehicle Engineering,Chongqing University,Chongqing 400044,P.R.China)

机构地区：[1]重庆大学机械与运载工程学院,重庆400044

出　　处：《重庆大学学报》2024年第9期14-29,共16页Journal of Chongqing University

基　　金：国家重点研发计划资助项目(2020YFB2010500)。

摘　　要：超声换能器是超声振动辅助切削装置的核心部件,为研制适用于高速干切的大振幅超声振动辅助切削装置,需先设计研制超声换能器。基于考虑刀具的二级放大超声换能器设计方法,遵循“变幅杆-超声换能器”一体式设计理念,结合ANSYS有限元软件的模态分析和谐响应分析结果,设计并研制了二级放大超声换能器。根据研制的二级放大超声换能器特性,系统设计并研制与其相匹配的超声波发生器、止转环、输电系统和刀柄壳结构。对二级放大超声换能器进行了阻抗分析和振幅测量等性能测试。对所设计研制的大振幅超声振动辅助高速干切装置开展实验测试分析,探究了其对难加工材料30CrMnSiNi2A加工表面质量的改善程度。结果表明:二级放大超声换能器纵向振动仿真结果与理论设计一致,二级放大超声换能器输出振幅稳定,在50%输出功率下纵振振幅为15.4μm,最大可达25.1μm,且输出振幅与功率百分比呈正相关,性能良好;所研制的大振幅超声振动辅助切削装置可大幅降低进给方向切削力和表面粗糙度,显著提高难加工材料加工表面质量,适用于难加工材料高速干切。The ultrasonic transducer is the core component of an ultrasonic vibration-assisted cutting device.To develop a large-amplitude ultrasonic vibration-assisted cutting device suitable for high-speed dry cutting,the first step is to design and develop the ultrasonic transducer.Based on the design method of the second-stage amplified ultrasonic transducer considering the tool,following the integrated design concept of amplifier-ultrasonic transducer,and combined with the results of modal analysis and harmonious response analysis using ANSYS finite element software,a two-stage amplified ultrasonic transducer was designed and developed.According to the characteristics of the developed two-stage amplified ultrasonic transducer,its matching ultrasonic generator,anti rotation ring,power transmission system,and tool holder shell structure were systematically designed and developed.Performance tests including impedance analysis and amplitude measurement were carried out for the developed two-stage amplified ultrasonic transducer.Experimental test and analysis of the designed and developed large-amplitude ultrasonic vibration-assisted high-speed dry cutting device were conducted to explore the improvement of surface quality in the difficult-to-machining material 30CrMnSiNi2A.The results show that the longitudinal ultrasonic vibration simulation results of the two-stage amplified ultrasonic transducer are consistent with the theoretical design,and the longitudinal vibration amplitude output is stable.The longitudinal vibration amplitude is 15.4μm at 50%output power and can reach a maximum of 25.1μm,with the output amplitude positively correlated with the power percentage,indicating good performance test results.The developed large-amplitude ultrasonic vibration-assisted cutting device greatly reduces the cutting force and surface roughness in the feeding direction,significantly improves the surface quality of difficult-to-machine materials,and is suitable for high-speed dry cutting of such materials.

关 键 词：二级放大超声换能器 有限元仿真分析 大振幅超声振动辅助切削装置 振幅 超声振动辅助高速干切 

分 类 号：TG663[金属学及工艺—金属切削加工及机床]