Design and Experimental Study of Ultrasonic Local Resonance System

doi:10.3969/j.issn.1000-1093.2019.08.026

Abstract

Abstract: In ultrasonic vibration machining, the cutting force and cutting heat are significantly reduced, the tool wear is reduced, and the machining efficiency is improved. The ultrasonic vibration machining process is widely used for machining the difficult-to-machine materials, such as hard and brittle materials. In order to avoid the influence of tool load on the resonant frequency, the local resonance theory is used to divide the vibration system into two subsystems. The frequency equation of complex acoustic system is derived from the total input impedance equal to zero at the junction of the subsystems, and the size of vibration system is calculated. Calculated results show that the modal analysis results and the actual measured results are less than 3% deviation from the theoretical values, which meets the design requirements and verifies the correctness of the theoretical design of local resonance. The acoustic system designed by this method is not affected by the tool load, the fluctuation of force during processing is small, and the stability of the system is improved to some extent, indicating that the local resonance system has a good processing effect. Key

Key words: tool, ultrasoniclocalresonance, vibrationsystem, frequencyequation, compoundresistancemethod, resistanceload, forceload

CLC Number:

TG663

LI Pengtao， ZHAO Bo， ZHAO Chongyang， WANG Yi. Design and Experimental Study of Ultrasonic Local Resonance System[J]. Acta Armamentarii, 2019, 40(8): 1747-1755.

References

［1］房善想, 赵慧玲, 张勤俭. 超声加工技术的应用现状及其发展趋势[J]. 机械工程学报, 2017, 53(19):22-32.
FANG S X, ZHAO H L, ZHANG Q J. The application status and development trends of ultrasonic machining technology[J]. Journal of Mechanical Engineering, 2017, 53(19):22-32.(in Chinese)
[2］ SHEN X H, XU G F. Study of milling force variation in ultrasonic vibration-assisted end milling[J]. Materials & Manufacturing Processes, 2017, 33(9): 644-650.
[3］ ZHAO B, JIA X F, CHEN F, et al. Control model and the experimental study on the ultrasonic vibration-assisted electrolytic in-process dressing internal grinding[J]. International Journal of Advanced Manufacturing Technology, 2017, 92(7/8):1-13.
[4］ ABBASI A, AMINI S, SHEIKHZADEH G A. Effect of ultrasonic peening technology on the thermal fatigue of rolling mill rolls[J]. International Journal of Advanced Manufacturing Technology, 2018,94(5/6/7/8):2499-2513.
[5］张园, 康仁科, 刘津廷, 等. 超声振动辅助钻削技术综述[J]. 机械工程学报,2017,53(19):33-34.
ZHANG Y,KANG R K, LIU J T, et al. Review of ultrasonic vibration assisted drilling[J]. Journal of Mechanical Engineering,2017,53(19):33-34.（in Chinese）
[6］别文博,赵波,王晓博,等.超声加工在齿轮抗疲劳制造中的研究综述与展望[J].表面技术,2018,47(7):35-51.
BIE W B, ZHAO B, WANG X B, et al. Overview and expectation on gear anti-fatigue manufacture by ultrasonic assisted machining[J]. Surface Technology,2018, 47(7): 35-51.(in Chinese)
[7］赵建, 王兵, 刘战强. 旋转超声滚压加工中的滚压力与滚压深度及表面形貌研究[J]. 兵工学报,2016,37(4):696-704.
ZHAO J,WANG B, LIU Z Q. The investigation into burnishing force, burnishing depth and surface morphology in rotary ultrasonic burnishing [J]. Acta Armamentarii, 2016, 37(4):696-704. (in Chinese)
[8］ LIAO Y S, CHEN Y C, LIN H M. Feasibility study of the ultrasonic vibration assisted drilling of Inconel superalloy[J]. International Journal of Machine Tools & Manufacture, 2007, 47(12/13):1988-1996.
[9］ BAGHLANI V, MEHBUDI P, AKBARI J, et al. An optimization technique on ultrasonic and cutting parameters for drilling and deep drilling of nickel-based high-strength Inconel 738LC superalloy with deeper and higher hole quality[J]. International Journal of Advanced Manufacturing Technology,2016, 82(5/6/7/8):1877- 1888.
[10］赵波, 陈凡, 贾晓凤, 等. 非谐振大工具头变幅杆优化设计及声学特性测试[J]. 陕西师范大学学报(自然科学版), 2017, 45(1):45-51.
ZHAO B, CHEN F, JIA X F, et al. Optimization design and characteristics test of non-resonant large tool head horn[J].Journal of Shaanxi Normal University (Natural Science Edition), 2017, 45(1):45-51.（in Chinese）
[11］付俊帆, 秦慧斌, 吕明. 基于Mindlin理论的功率超声纵弯谐振变幅器设计理论与实验研究[J]. 振动与冲击, 2018, 37(7): 259-266.
FU J F, QIN H B, L M. Design and experiment of ultrasonic longitudinal-flexural resonance transducer based on Mindlin theory[J]. Journal of Vibration and Shock, 2018, 37(7):259-266.（in Chinese）
[12］梁欣, 吕明, 秦慧斌,等. 纵向谐振变幅器的非谐振设计理论研究与验证[J]. 机械设计与制造, 2016 ,3(3):5-9.
LIANG X, L M, QIN H B, et al. Research and verification on the Nonnon-resonant design theory of longitudinal vibration transformer[J]. Machinery Design and Manufacture, 2016, 3(3): 5- 9.（in Chinese）
[13］范国良, 应崇福, 林忠茂, 等. 一种新型的超声加工深小孔的工具系统[J].应用声学, 1982 (1):2-7.
FAN G L, YING C F, LIN Z M, et al. A new tool system for deep small holes machined by ultrasonic machining [J]. Applied Acoustics, 1982(1): 2-7.（in Chinese）
[14］赵波, 何定东. 超声珩磨局部共振问题研究[J]. 现代制造工程, 1998,6(6):4-5.
ZHAO B, HE D D. Research on local resonance of ultrasonic honing[J]. Modern Manufacturing Engineering, 1998,6(6): 4-5.（in Chinese）
[15］徐可伟, 朱训生, 赵波. 用谐振来解释超声加工中的“局部共振”现象[J]. 应用声学, 2002, 21(5):30-33.
X K W, ZHU X S, ZHAO B. Using resonance to explain the phenomenon of “local resonance” in ultrasonic machining[J]. Applied Acoustics, 2002, 21(5): 30-33. （in Chinese）
[16］应崇福, 范国良. 超声复合振动系统中的“ 局部共振” 现象——20 年来的应用和机理分析情况[J].应用声学, 2002, 21(1):19-25.
YING C F, FAN G L. The phenomenon of“local resonance” in compound ultrasonic vibration systems—applications and mechanism analyses during the 20 years after its discovery [J]. Journal of Applied Acoustics, 2002, 21(1):19-25. （in Chinese）
[17］郑建新, 刘传绍, 高国富, 等. 超声振动钻削中局部共振现象的研究与应用[J]. 工具技术, 2003, 37(2):5-8.
ZHENG J X, LIU C S, GAO G F, et al. Research and application of local resonance phenomenon in ultrasonic vibration drilling[J]. Chinese Tool Engineering, 2003,37(2):5-8.（in Chinese）
[18］周光平, 鲍善惠, 程存弟，等. “局部共振”现象的理论解释[J]. 应用声学,1994, 13(6):39-42.
ZHOU G P, BAO S H, CHENG C D, et al. The theory explanation of the phenomenon of“local resonance” [J]. Applied Acoustics, 1994,13(6):39-42. （in Chinese）
[19］鲍善惠.超声耦合振动与“局部共振”现象[J].应用声学,1998, 17(4):6-10.
BAO S H. Ultrasonic coupled vibration and “local resonance” phenomenon [J]. Applied Acoustics, 1998, 17(4):6-10.（in Chinese）
[20］赵福令, 冯冬菊, 郭东明, 等. 超声变幅杆的四端网络法设计[J].声学学报,2002, 27(6): 554-558.
ZHAO F L, FENG D J, GUO D M, et al. Design of four terminal network method for ultrasonic horn[J]. Journal of Acoustics, 2002, 27(6):554-558.（in Chinese）
[21］张宁宁.指数型复合变幅杆的设计及负载特性研究[J].机械制造,2014,52(10):24-46.
ZHANG N N. Design and load characteristics of an exponential composite horn[J]. Machinery, 2014, 52(10):24-46.（in Chinese）

第40卷
第8期2019 年8月兵工学报ACTA
ARMAMENTARIIVol.40No.8Aug.2019

[1]	WANG Weiping, WANG Qi, YU Yang. Fault Identification of Machine Tool Spindle System Based on Attention Mechanism and Deep Learning Algorithm [J]. Acta Armamentarii, 2022, 43(4): 861-875.
[2]	QIN Guohua， GAO Jie， YE Haichao， JIANG Guojie， HUANG Shuai， LAI Xiaochuun. Tool Wear Prediction Based on Fusion Evaluation Index and Neural Network [J]. Acta Armamentarii, 2021, 42(9): 2013-2023.
[3]	LI Heng, YE Zukun, ZHA Wenbin, WANG Yulin. Tool Wear Online Monitoring Based on Multi-sensor Information Decision-making Level Fusion [J]. Acta Armamentarii, 2021, 42(9): 2024-2031.
[4]	HUANG Tao, LIU Zhi-bing, WANG Xi-bin, PAN Lin, YAN Zheng-hu, LENG Shou-yang. Effect of Inclination Angle of Cutter Shaft on Machining Deformation of Thin-walled Blade [J]. Acta Armamentarii, 2018, 39(3): 577-583.
[5]	LI Chao, KONG Ling-fei, LIANG Yan-ming, JIANG He-ling, YAN Dong. Prediction Method for Roundness Error of Machined Deep-hole Based on Vibration Behaviors of Cutting Tools [J]. Acta Armamentarii, 2018, 39(2): 364-372.
[6]	WANG Kai， SUN Jian-fei， DU Da-xi， CHEN Wu-yi. Quantitative Experimental Analysis on Crater Wear of Cemented Carbide Tools [J]. Acta Armamentarii, 2017, 38(8): 1578-1585.
[7]	ZHAO Jian-she， ZHOU Xue-de， ZHOU Xu-jiao， WANG Wen-feng. Synchronous Design of Electrode and Its Feeding Path in EDM for Cowled Integral Impeller [J]. Acta Armamentarii, 2017, 38(4): 744-749.
[8]	KONG Ling-fei, NIU Han, HOU Xiao-li, LIN Hong-bin, WANG Jie. Influence of Tool Vibration Characteristics on the Hole Roundness Morphology in BTA Deep-hole Drilling [J]. Acta Armamentarii, 2016, 37(6): 1066-1074.
[9]	WANG Xin-gang， LYU Chun-mei， ZHAO Yu-qian， CHEN Xiao-ming. Research on Failure-rate-based Tool Replacing Strategy [J]. Acta Armamentarii, 2016, 37(5): 903-908.
[10]	YANG Zhou, ZHU Yun-peng, ZHANG Yi-min, REN Hong-rui. A Comprehensive Reliability Allocation Method for Numerical-controlled Lathes Based on Copula Function [J]. Acta Armamentarii, 2016, 37(1): 131-140.
[11]	CHEN Jian, TIAN Liang , SHANG Hong-mo , ZHENG Deng-sheng, WANG Gui-cheng. Identification of Joint Part Parameters of HSK Spindle-toolholder Based on Closed-form Approach [J]. Acta Armamentarii, 2015, 36(7): 1309-1317.
[12]	JIANG Zhen-xi, SUN Jie, LI Guo-chao, JIA Xing-min, LI Jian-feng. Investigation on the Relationship among Tool WearCutting Force and Vibration in Milling of TC4 [J]. Acta Armamentarii, 2015, 36(1): 144-150.
[13]	WANG Xin-gang， LI He, LYU Chun-mei, WANG Xue-ling₂, PANG Xu₂. Research on Dynamic Reliability Sensitivity of Hard Alloy Cutting Tool [J]. Acta Armamentarii, 2014, 35(1): 114-119.
[14]	HUANG Xian-zhen, WU Mao-chang, ZHANG Yi-min, HU Nai-tao. Research on Reliability-based Robust Design Method for Rotation Systems of CNC Turrets [J]. Acta Armamentarii, 2013, 34(9): 1132-1136.
[15]	QIN Guo-hua, ZHANG Yun-jian, YE Hai-chao. A Neural Network-Based Prediction Method of Machining Deformation for Thin-walled Workpiece [J]. Acta Armamentarii, 2013, 34(7): 840-845.