双弯曲旋转超声椭圆振动加工系统设计

邵壮壮; 郑侃; 董松; 孙振文; 孙连军; 严嘉文

doi:10.13700/j.bh.1001-5965.2022.0712

双弯曲旋转超声椭圆振动加工系统设计

doi: 10.13700/j.bh.1001-5965.2022.0712

南京理工大学机械工程学院，南京 210094

基金项目: 国家自然科学基金(52075265)

详细信息

通讯作者:
E-mail：zhengkan@njust.edu.cn

中图分类号: TH161
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出版历程
- 收稿日期: 2022-08-13
- 录用日期: 2022-10-07
- 网络出版日期: 2023-01-06
- 整期出版日期: 2024-09-27

Design of double bending rotary ultrasonic elliptical vibration machining system

College of Mechanical Engineering，Nanjing University of Science and Technology，Nanjing 210094，China

Funds: National Natural Science Foundation of China (52075265)

More Information

Corresponding author: E-mail：zhengkan@njust.edu.cn

摘要

摘要:
由于旋转超声单一振动模式加工效率提升有限，因此采用超声振动激励源耦合法设计了一种双弯曲旋转超声椭圆振动加工系统。推导弯曲波动方程，计算的弯曲超声振动系统参数与仿真结果的理论分析误差仅为5%。耦合双弯曲旋转超声椭圆振动加工系统2个不同方向的振动，控制弯振频率偏差低于1%。对超声刀柄的法兰位置与形状进行有限元分析发现，开设减振槽有利于增大弯振振幅，并确定了法兰的最佳位置。对双弯曲旋转超声椭圆振动加工系统的振动频率和振幅进行测试，结果表明：所设计系统在工作频率和2个方向的振幅均满足设计预期。
- 双弯曲超声椭圆振动 /
- 激励源耦合 /
- 超声刀柄 /
- 弯振频率 /
- 弯振振幅
Abstract:
The processing efficiency of the rotary ultrasonic single vibration mode is limited. Therefore, an elliptical vibration processing system with double-bending ultrasonic vibrations was designed using the ultrasonic vibration excitation source coupling method. The bending wave equation was derived, and the calculated parameters of the bending ultrasonic vibration system showed only a 5% error compared to the simulation results in theoretical analysis. The coupled double-bending rotary ultrasonic elliptical vibration processing system combines vibrations in two different directions, controlling the bending vibration frequency deviation to be less than 1%. Finite element analysis was performed on the flange position and shape of the ultrasonic tool holder, revealing that the inclusion of damping grooves helps increase the bending vibration amplitude and determines the optimal position of the flange. Finally, the vibration frequency and amplitude of the double-bending rotary ultrasonic elliptical vibration processing system were tested, and the results indicated that the operating frequency and amplitudes in both directions met the design expectations.
- double-bend ultrasonic elliptical vibration /
- excitation source coupling /
- ultrasonic shank /
- bending vibration /
- bending vibration amplitude

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图 1 超声振动加工系统原理

Figure 1. Principle of ultrasonic vibration machining system

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图 2 一组弯振压电陶瓷堆结构示意图

Figure 2. Structural diagram of a set of piezoelectric ceramic stack

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图 3 双弯曲旋转超声振动换能器椭圆振动工作原理

Figure 3. Working principle of elliptical vibration of double-bending rotary ultrasonic vibration transducer

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图 4 双弯曲变幅杆结构

Figure 4. Double bending horn structure

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图 5 无法兰超声系统模态云图

Figure 5. Modal cloud atlas of ultrasonic system with unmovable flange

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图 6 双弯曲旋转超声椭圆振动加工系统网格

Figure 6. Double-bending rotary ultrasonic elliptical vibration machining system grid

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图 7 双弯曲旋转超声椭圆振动加工系统振型云图

Figure 7. Modal cloud atlas of dual-bending rotary ultrasonic elliptical vibration machining system

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图 8 法兰位置与振幅关系

Figure 8. Relationship between flange position and amplitude

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图 9 双弯曲旋转超声椭圆振动加工系统弯曲振幅

Figure 9. Bending amplitude of double bending rotary ultrasonic elliptical vibration machining system

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图 10 阻抗分析

Figure 10. Impedance analysis

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图 11 x和y方向的振动幅值测量及结果

Figure 11. Vibration amplitude measurement and results in different directions

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图 12 不同方向的电压与振幅关系

Figure 12. Relationship between voltage and amplitude in different directions

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表 1 材料属性

Table 1. Material properties

材料	密度/(kg·m⁻³)	杨氏模量/GPa	泊松比
45#钢	7850	208	0.28
PZT-8	7650	90	0.3

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表 2 超声振动系统各零件有限元分析材料属性

Table 2. Material properties of ultrasonic vibration system by finite element analysis

零件	材料	密度/(kg·m³)	弹性模量/Pa	泊松比
后盖板	45#钢	7800	2.08×10¹¹	0.28
前盖板	45#钢	7800	2.08×10¹¹	0.28
压电陶瓷	PZT-8	7800	8.2×10¹⁰	0.29
预紧螺栓	40cr	7900	2.14×10¹¹	0.3
刀具	硬质合金YG8	14000	1.9×10¹¹	0.3

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表 3 双弯曲旋转超声椭圆振动加工系统弯曲频率

Table 3. Bending frequency of double bending rotary ultrasonic elliptical vibration machining system

法兰距离/mm	x方向自由频率/Hz	y方向自由频率/Hz	x方向固定频率/Hz	y方向固定频率/Hz
14	22410	22414	23480	23528
14.5	22301	22405	23619	23569
15	22596	22693	23535	23574
15.5	22281	22385	23761	23812
16	22269	22375	23856	23914

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