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为了改善传统铣削钛合金的加工条件,研究了进给方向超声振动辅助铣削对切削力的影响。定值计算了不同振动频率、振幅、铣削速度时的净切削时间比,建立了对工件施加超声振动的铣削加工三维有限元模型,根据仿真结果讨论了加工参数对进给方向切削力瞬时值的影响,并结合净切削时间比分析了加工参数对三个方向切削力平均值的影响。研究表明:施加超声振动后切削力明显减小;振动频率小于40kHz和振幅小于30μm时切削力平均值同净切削时间比变化趋势一致,当频率或振幅超过上述值时,刀具、工件间的摩擦力对切削力平均值的影响显著。 相似文献
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一、陶瓷精密切削法分析陶瓷的精密切削法是通过刀具的尖端将陶瓷有规则,一点一点地不断产生崩裂的切削方法,具体如下: 1.利用脉冲切削波形精密切削陶瓷利用作用时间短的脉冲状切削力波形,使陶瓷在刀具的刀尖附近产生崩裂。其金刚石车刀以频率f、振幅a在切削方向进行超声波振动,通过振动切削来作用于陶瓷。由于脉冲切削力波形的作用,使得在车床主轴卡盘上所夹持的陶瓷工件吃刀分力方向的弹簧常数K提高T/tc倍,从而可取得刚性化效果。 2.用间断脉冲波形切削力精密切削陶瓷根据振动切削,使间断脉冲切削力波形产生作用进行重叠振动切削。这种间断的脉 相似文献
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超声振动车削TC4钛合金的切削性能研究 总被引:1,自引:0,他引:1
为了探究超声振动车削过程中切削力和切削温度的变化规律,使用Third Wave Advant Edge切削仿真软件,基于POWER-LOW本构模型和ALE网格划分方法建立TC4钛合金车削加工的有限元模型,获得传统车削与超声振动车削的切削力和最高切削温度变化情况。结合超声振动车削中刀具切削速度和位移变化规律,对传统车削与超声振动车削的切削力和最高切削温度变化规律展开对比分析;探究超声振动车削中的工件进给速度、刀具振频和振幅对切削力的影响规律,实现各加工参数的最优组合,为实际加工提供参考。 相似文献
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《工具技术》2018,(12)
振动是金属加工过程中的一个复杂问题,其形成的颤振不仅限制了机床加工效率的提高,还对机床和切削刀具造成很大的危害。对数控加工特别是高速加工过程中颤振的研究和控制技术是先进制造技术的重要研究课题,本文介绍了切削动力学建模的两个环节:切削力建模和刀具—工件动力学建模;根据切削力建模方式的不同,将其归纳为基于试验的经验公式建模法、解析建模法和基于人工智能及软件技术切削力建模法;根据铣削加工过程中稳定区域的不同预测方式,切削稳定性分析方法分为时域分析方法、频域分析方法、试验分析方法,并对三种方法的优势和不足进行对比分析;对切削颤振的抑制措施进行了总结介绍;展望了高速切削加工稳定性研究的关键技术,为切削加工振动的理论研究与工业应用提供借鉴和参考。 相似文献
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对微织构刀具在超声振动辅助加工时的切削性能进行仿真研究。在研究中,在CAXA软件中建立刀具参数相同的二维刀具和微织构刀具,导入AdvantEdge软件,分别进行二维普通刀具切削、二维微织构刀具切削、二维普通刀具超声振动切削、二维微织构刀具超声振动切削,对比分析四种切削的仿真结果。通过仿真研究发现,微织构结构可以有效降低刀具温度,高温区域明显减小,同时可以减小刀具应力,减小高应力区域,对切削力的影响则不大。超声振动辅助加工可以有效减小切削力,降小刀具应力,对刀具温度的影响则不大。微织构结构和超声振动辅助加工同时作用,刀具温度最低,切削力和应力最小,并且可以延长刀具寿命。 相似文献
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《制造技术与机床》2021,(9)
大螺距螺杆在精加工的过程中,其径向切深大,参与切削的切削刃长,进给速度大,使其切削力数十倍增加,造成刀具振动剧烈,热力耦合场不稳定,加剧了刀具的磨损,刀具的振动和磨损是造成工件表面质量劣化的主要原因。通过进行切削优化的研究,可以解决工件表面质量差的问题。首先,比较机器学习与回归方式的拟合误差,选用精确性更高的机器学习方法建立了切削力和切削温度的预测模型。其次,采用不同的群智能算法对优化目标进行求解,比较不同算法的求解性能,选择人工蜂群算法的优化结果为最优参数组合。最后,对不同切削方案得到的工件表面粗糙度进行测量,结果表明:采用优化后的参数加工,得到的工件表面粗糙度下降了20%,改善了工件表面质量,达到了切削优化的目的。 相似文献
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In this study, a novel dynamic contour error compensation technique has been proposed for the elliptical vibration cutting process achieved through the ultra-precision amplitude control. The influence of the contour error, triggered due to the inertial vibrations of the friction-less feed drive system, on the machining accuracy deterioration has been experimentally investigated. In order to reduce the contour error, a compensation method utilizing a real-time amplitude control in the elliptical vibration cutting process has been applied. In the proposed method, the dynamic motion error along the depth of cut direction is detected by utilizing the precise linear encoders installed on the feed drive system. The motion error in real-time is subsequently converted into cancelling amplitude command for the vibration control system of the ultrasonic vibrator, thus, guaranteeing that the envelope of the vibration amplitudes auto-tracks the dynamic reference position of the motion axis in the depth of cut direction. Due to this, a constant nominal depth of cut can be obtained even though the inertial vibrations disturb the feed drive control during machining. A series of experimental investigations have been conducted in order to analyze the machining performance by employing the proposed method. The maximum machining error is observed to significantly decrease from 0.6 to 0.04 μm by applying the proposed compensation method. Finally, the micro dimple array with a structural height from about 200 to 600 nm could be accurately fabricated with a maximum machining error of 36.8 nm, which verified the feasibility of the proposed amplitude control compensation method. 相似文献
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This paper studies the nano-structure fabrication on hardened steel by means of elliptical vibration cutting equipped with the ultra-precision amplitude control sculpturing method. Machining performance of the amplitude control sculpturing method is investigated, and the limitation in nano-scale machining is explored. In this proposed method, machinable part geometry is essentially restricted by vibration conditions and tool geometry. In addition, a considerable error between the amplitude command and the envelope of the tool trajectory is generated when the slope of the machining part geometry becomes steep. To overcome this error, a compensation method for the amplitude control command is proposed. In order to clarify the machining performance of the proposed technology, a series of analytical and experimental investigations are conducted. Furthermore, by applying the proposed command compensation method, nano-structures with a large ratio of structure height to wave length are machined accurately. The proposed sculpturing method is subsequently applied to the machining of nano-textured grooves and a three-dimensional grid surface, which verifies the feasibility of the proposed amplitude control sculpturing method. 相似文献
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A new ultra-precision sculpturing method in micro/nano scale for difficult-to-cut materials is proposed in the present research. Elliptical vibration cutting technology is well-known for its excellent performance in achieving ultra-precision machining of steel materials with single crystal diamond tools. Elliptical vibration locus is generally controlled and held to a constant in practice. On the contrary, the proposed method utilizes the variations of the elliptical vibration locus in a positive manner. Depth of cut can be actively controlled in elliptical vibration cutting by controlling vibration amplitude in the thrust direction. By utilizing this as a fast tool servo function in elliptical vibration cutting, high performance micro/nano sculpturing can be attained without using conventional fast tool servo technology. A high-speed amplitude control system is developed for elliptical vibration, with a bandwidth of more than 300 Hz, where the vibration amplitude can be controlled within 4 μmp-p. The developed control system is applied to sculpturing ultra-precision nano textured grooves on hardened steel with single crystal diamond tools. It is confirmed that the textured grooves have the desired shapes, and their profiles agree well with the vibration amplitude commands input to the control system. Further, a high performance micro/nano sculpturing system for plane surfaces is developed, where the vibration amplitude is controlled in synchronization with the planing motion of an ultra-precision machine tool. Nano sculpturing experiments on hardened steel, carried out by the developed system, are reported, as well as consequent picture images and a variety of dimple patterns that were formed successfully on the hardened steel as nano-scale sculptures. 相似文献
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AbstractAdding ultrasonic vibrations to conventional turning can improve the process in terms of cutting force, surface finish and so on. One of the most important factors in machining is the heat generation during the cutting process. In ultrasonic-assisted turning (UAT) the tool tip also vibrates at very high frequency and this sinusoidal motion causes complexity in heat modeling of the cutting system. Modeling and simulation of cutting processes can help to understand the nature of process and provides information to select optimum conditions and machining parameters. In this article, a finite element model has been developed for predicting tool tip temperature in UAT. The effect of machining parameters including cutting speed, feed rate and amplitude of vibration on the tool tip temperature has been investigated. In order to simplify the machining process, the cutting experiment has been carried out in dry condition. The results showed that by applying ultrasonic vibration to the cutting tool, the tool tip flash temperature increases but in some condition its average value could be less than the conventional machining. 相似文献
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Sen YIN Yan BAO Yanan PAN Zhigang DONG Zhuji JIN Renke KANG 《Frontiers of Mechanical Engineering》2022,17(4):59
Nanoscale surface roughness of tungsten heavy alloy components is required in the nuclear industry and precision instruments. In this study, a high-performance ultrasonic elliptical vibration cutting (UEVC) system is developed to solve the precision machining problem of tungsten heavy alloy. A new design method of stepped bending vibration horn based on Timoshenko’s theory is first proposed, and its design process is greatly simplified. The arrangement and working principle of piezoelectric transducers on the ultrasonic vibrator using the fifth resonant mode of bending are analyzed to realize the dual-bending vibration modes. A cutting tool is installed at the end of the ultrasonic vibration unit to output the ultrasonic elliptical vibration locus, which is verified by finite element method. The vibration unit can display different three-degree-of-freedom (3-DOF) UEVC characteristics by adjusting the corresponding position of the unit and workpiece. A dual-channel ultrasonic power supply is developed to excite the ultrasonic vibration unit, which makes the UEVC system present the resonant frequency of 41 kHz and the maximum amplitude of 14.2 μm. Different microtopography and surface roughness are obtained by the cutting experiments of tungsten heavy alloy hemispherical workpiece with the UEVC system, which validates the proposed design’s technical capability and provides optimization basis for further improving the machining quality of the curved surface components of tungsten heavy alloy. 相似文献