Design and application of large load amplitude transformer in ELID compound internal grinding system assisted by ultrasonic vibration
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摘要: 为解决超声振动辅助ELID复合内圆(UAEI)磨削陶瓷等硬脆材料的声学系统设计难题,对驱动几何尺寸大、质量重的金属结合剂金刚石砂轮用的小端较长的变幅器进行理论设计及优化。基于弹性波在介质中的传播规律,利用MATLAB确定变幅器取值方案,再根据加工要求并结合ANSYS模态分析筛选出符合要求的方案,然后采用零阶算法进一步优化处理,得到满足几何尺寸、应力及振动频率要求的变幅器尺寸。对设计出的变幅器进行振动特性测试,其谐振频率理论误差为0.192%~1.824%,符合预期设计要求。采用研制出的UAEI磨削系统进行加工特性测试,与在线电解修整砂轮(ELID)内圆磨削比较,其工件的表面粗糙度降低了44.2%,且工件三维形貌更加平整,砂轮表面状况获得改善。Abstract: A theoretical design, followed by optimization, of the amplitude transformer was carried out, which had longer small end for driving metal bonded diamond wheel with large size and heavy mass, to solve the problem of acoustic system design in ultrasonic vibration assisted ELID compound internal(UAEI)grinding of hard & brittle materials such as ceramics.Based on the propagation law of elastic wave in the medium, the value selection scheme of the amplitude transformer was determined by MATLAB, and then the scheme that met the requirements was selected according to both processing requirements and ANSYS modal analysis.Then the zero order algorithm was used to further optimize the processing, and the size of the amplitude transformer that met the requirements of geometric size, stress and vibration frequency was obtained.The vibration characteristics of the designed amplitude transformer are tested, whose resonance frequency error is within 0.192% to 1.824%, satisfying the expected design requirements.The machining characteristics of the developed UAEI grinding system are tested and compared with those of ELID.The surface roughness of the workpiece is reduced by 44.2%, and that the 3D shape of the workpiece is more flat with improved surface of the grinding wheel.
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Key words:
- UAEI grinding /
- hard brittle material /
- amplitude transformer design /
- finite element
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