氧化锆陶瓷超声旋转钻削振动系统改进设计及实验研究

发布时间：2018-03-20 00:20

本文选题：超声旋转加工　切入点：振动系统　出处：《广东工业大学》2017年硕士论文　论文类型：学位论文

【摘要】：陶瓷等硬脆性材料具有优良的物理和机械性能,但其高硬度和高脆性使得这些材料的加工变得困难。超声旋转加工是一种几乎适用于各种硬脆性材料的高效加工的方法。本文针对超声旋转加工技术中存在的问题,进行了振动系统的设计以及氧化锆陶瓷的实验研究。本文完成的理论分析对企业机床中超声旋转钻削振动系统的设计具有良好的指导作用,对降低加工切削力与工具磨损的工艺参数的选取提供参考。本文的主要研究方法及结论如下:(1)根据振动系统的各组成部分对材料的特殊要求选择合适的材料,并运用一维纵振理论对该振动系统的结构做初步的理论设计,确定各部分的尺寸形状,建立振动系统(夹心式换能器-两级阶梯型一体式变幅杆-工具)的三维模型,为动力学分析奠定基础,设计的振动系统的谐振频率为40kHz。(2)采用ANSYS软件进行振动系统的动力学分析(模态分析和谐响应分析),并采用基于频率灵敏度的方法对其频率进行优化,主要针对其谐振频率、节点位置以及振幅进行分析。结果显示:其谐振频率为40.05kHz,与理论设计值相比,误差仅为0.125%;节点位置分别处于安装环的位置以及靠近工具夹持位置;在施加驱动电压为150V时,振幅可达到6.5μm,满足设计的要求。(3)采用安捷伦阻抗分析仪进行阻抗测试,验证该振动系统工作频率的仿真结果。结果表明:超声振动系统的阻抗曲线和相位曲线比较平滑,没有杂波,其谐振频率为39.74kHz,与仿真分析的结果相比,误差为0.77%,符合设计要求。(4)运用激光干涉原理搭建振幅测试平台,对振动系统的振动幅度进行测试,结果表明:在固定的工具外露长度(20mm)下,其超声振幅在一定的范围内随着谐振电压的不断增加而增大,并几乎呈线性关系,最大振幅可达到8.08μm。安装环处的振动仅为磨头端部振动的1.87%,可忽略不计;压帽处的振动仅为磨头端部振动的3.12%,相比于单节点的振动系统(压帽处的振动为磨头端部振动的37.5%)缩小近10倍。设计的振动系统的性能能满足预期设计的要求。(5)以超声能量、主轴转速和进给速度作为实验研究的工艺参数,以切削力、工具磨损量作为评价指标对氧化铝陶瓷材料进行孔加工实验,采用激光共聚焦显微镜观察工具表面的形貌,探讨超声旋转加工中工具磨损机理。结果表明:针对氧化锆陶瓷材料,超声旋转加工方法相比传统的加工方法能有效地降低切削力并减少工具的磨损量;在超声旋转加工的过程中,随着加工孔数的不断增加,最大切削力呈现先逐渐增大再缓慢减小的趋势,并且在一定范围内,工具磨损量会随着超声能量、主轴转速以及进给速度的增加而增加,其中进给速度对工具磨损的影响最大,其次是超声能量即振幅大小,最后为主轴转速;超声旋转加工氧化锆陶瓷的工具磨损机理主要包括磨耗磨损、磨粒破碎以及磨粒脱落,其中以磨粒脱落为主。
[Abstract]:Ceramic and other hard brittle materials with excellent physical and mechanical properties, but its high hardness and high brittleness of the processing of these materials becomes difficult. Rotary ultrasonic machining is a machining method, suitable for almost all kinds of hard and brittle materials. Aiming at the existing problems in rotary ultrasonic machining technology, the design of vibration system experimental study of zirconia ceramics. The theoretical analysis of ultrasonic machine tool rotary drill design enterprise cutting vibration system has good guidance, to provide the reference for the selection of lower cutting force and tool wear process parameters. The main research methods and conclusions are as follows: (1) according to each part the vibration system of the special requirements for material selection of appropriate materials, and the use of one-dimensional longitudinal vibration theory theory to design the basic structure of the vibration system, determine the part The size and the shape of building vibration system (sandwich transducer - two ladder type integrated horn - tool) 3D model, lay the foundation for the dynamic analysis, the vibration frequency of the vibration system design for 40kHz. (2) dynamic analysis of vibration system by using ANSYS software (modal analysis and harmonic response analysis), and by using the method of frequency sensitivity based on the frequency optimization, mainly aiming at its resonant frequency, amplitude and node location were analyzed. The results show that the resonant frequency is 40.05kHz, compared with the theoretical design value, the error is 0.125%; the node position respectively in the mounting ring position and near the tool clamping position; the driving voltage applied for 150V, the amplitude can reach 6.5 m, meet the design requirements. (3) impedance test using Agilent impedance analyzer to verify the simulation results, the working frequency of the vibration system. Results The impedance and phase curves of the ultrasonic vibration system is quite smooth, no clutter, the resonant frequency is 39.74kHz, compared with the simulation results, the error is 0.77%, meet the design requirements. (4) to build a test platform by using the interference principle of amplitude laser test on vibration amplitude of vibration system the results show that: in the the tool exposed fixed length (20mm), the amplitude of ultrasonic vibration in a certain range with the increase of the resonant voltage increases, and almost a linear relationship, the maximum amplitude of vibration can reach 8.08 M. installed at ring only head of vibration at the end of 1.87%, can be ignored; only the vibration pressure cap as the head of vibration at the end of 3.12%, compared to the single node of the system vibration (vibration pressure cap for head end vibration 37.5%) reduced nearly 10 times. The performance of the vibration system design can meet the expected design requirements. (5) by ultrasonic energy, The spindle speed and feed speed as experimental study of technological parameters, cutting force, tool wear value as the evaluation index of hole machining experiments on alumina ceramic materials, using microscope observation tool surface confocal laser, explore the tool wear mechanism in rotary ultrasonic machining. The results show that the zirconia ceramic material, rotary ultrasonic machining compared with the traditional processing method can effectively reduce the cutting force and the amount of reduction of tool wear; in the process of rotary ultrasonic machining, with the increase of processing hole number, maximum cutting force is gradually increased and then slowly decreased, and in a certain range, the amount of tool wear with increasing ultrasonic energy. The spindle speed and the feed speed is increased, the effect of feeding speed on tool wear is the largest, followed by the amplitude of the ultrasonic energy, after the spindle Speed, the tool wear mechanism of ultrasonic rotating zirconia ceramics mainly includes wear wear, abrasive breakage and debris fall off, among which abrasive debris is mainly.

【学位授予单位】：广东工业大学
【学位级别】：硕士
【学位授予年份】：2017
【分类号】：TQ174.6

【参考文献】