耦合式超声复合加工装置的设计研究
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摘要
在难加工材料和精密加工中,功率超声加工技术具有普通加工无法比拟的工艺效果,将超声加工和其他加工方法相结合进行复合加工,常常能大幅度地提高加工速度、提高加工质量和完成一般加工方法难以完成的加工工作。因此,被广泛地应用于国民经济的各部门,并有广阔的应用前景。
本课题针对功率超声加工技术在复合加工中的应用,设计一套超声加工系统。运用分块设计的方法将此装置划分为超声换能器、超声变幅杆、超声发生器和匹配电路四大主要模块进行设计。超声换能器选用夹心式压电换能器结构,运用频率方程和等效电路法进行换能器材料的选择和结构尺寸的设计;超声变幅杆选用阶梯形变幅杆结构,运用半波长变幅杆设计方法进行结构和尺寸的设计;超声发生器的设计采用他激式电路结构,选择相应的功能模块和元器件,完成电路的设计;匹配电路运用变压器进行阻抗匹配,提出耦合式变压器匹配的方法,并设计变压器的各项参数,同时计算所需感性元件的数值,用以补偿压电换能器的容性阻抗。在各部分模块设计完成后,运用阻抗分析仪进行振动系统性能的检测,确保其符合设计要求;对电路部分进行相应测试,确保其输出有效的电振荡信号。
In the area of difficult machining materials and precision machining, the power ultrasonic processing technology has technological effect that are unexampled common processing technology. If the combined machining technology by ultrasonic with other processing method is used, the processing speed and quality can be improved greatly. And the combined machining can carry the processing work that can not be carryed by other common processing method. So it is widely used in many department of national economy and has wide application prospect.
The task of this subject is to design the processing equipment of ultrasonic for the use of the combined machining technology. The equipment is divided into four parts. They are ultrasonic generator, ultrasonic transducer, amplitude transformer, and matching circuit. The sandwich piezoelectric ultrasonic transducer is adopted when ultrasonic transducer is designed. Its material is chosen and its structure and dimension are designed using the frequency equation and equivalent circuit method. The stepped ultrasonic horn is adopted when amplitude transformer is designed. Its structure and dimension are designed with the method of half-wavelength design. The separately excited circuit structure is adopted when ultrasonic generator is designed. Function module and components are chosen. Then the design of circuit is completed. In the design process of matching circuit, impedance matching is performed with transformer. The method is put forward to match with coupling transformer. The parameters of transformer are calculated. And the numerical value of inductive element is calculated to compensate the capacitive load. After the design of four parts, the performance of vibration system is detected with to make sure it accords with design requirements. And the circuit is tested to make sure it can output oscillating signal.
本课题针对功率超声加工技术在复合加工中的应用,设计一套超声加工系统。运用分块设计的方法将此装置划分为超声换能器、超声变幅杆、超声发生器和匹配电路四大主要模块进行设计。超声换能器选用夹心式压电换能器结构,运用频率方程和等效电路法进行换能器材料的选择和结构尺寸的设计;超声变幅杆选用阶梯形变幅杆结构,运用半波长变幅杆设计方法进行结构和尺寸的设计;超声发生器的设计采用他激式电路结构,选择相应的功能模块和元器件,完成电路的设计;匹配电路运用变压器进行阻抗匹配,提出耦合式变压器匹配的方法,并设计变压器的各项参数,同时计算所需感性元件的数值,用以补偿压电换能器的容性阻抗。在各部分模块设计完成后,运用阻抗分析仪进行振动系统性能的检测,确保其符合设计要求;对电路部分进行相应测试,确保其输出有效的电振荡信号。
In the area of difficult machining materials and precision machining, the power ultrasonic processing technology has technological effect that are unexampled common processing technology. If the combined machining technology by ultrasonic with other processing method is used, the processing speed and quality can be improved greatly. And the combined machining can carry the processing work that can not be carryed by other common processing method. So it is widely used in many department of national economy and has wide application prospect.
The task of this subject is to design the processing equipment of ultrasonic for the use of the combined machining technology. The equipment is divided into four parts. They are ultrasonic generator, ultrasonic transducer, amplitude transformer, and matching circuit. The sandwich piezoelectric ultrasonic transducer is adopted when ultrasonic transducer is designed. Its material is chosen and its structure and dimension are designed using the frequency equation and equivalent circuit method. The stepped ultrasonic horn is adopted when amplitude transformer is designed. Its structure and dimension are designed with the method of half-wavelength design. The separately excited circuit structure is adopted when ultrasonic generator is designed. Function module and components are chosen. Then the design of circuit is completed. In the design process of matching circuit, impedance matching is performed with transformer. The method is put forward to match with coupling transformer. The parameters of transformer are calculated. And the numerical value of inductive element is calculated to compensate the capacitive load. After the design of four parts, the performance of vibration system is detected with to make sure it accords with design requirements. And the circuit is tested to make sure it can output oscillating signal.
引文
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[18]毛赛君.非接触感应电能传输系统关键技术研究,[硕士学位论文].南京:南京航空航天大学,2006.
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[21] Kenrichi Ishikawa,Hitoshi Suwabe,Tetsuhiro Nishide.A study on combined vibration drilling by ultrasonic and low-frequency vibrations for hard and brittle materials.Precision Engineering, 1998,22:196～205.
[22]温任林,颜景平.压电式超声振动切削系统的研究.东南大学学报,1997,27 (2):90～94.
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[24]沈金福.他山之石可以攻玉——DMG集团的激光切削加工机床和超声振动加工机床给人们的启示.世界制造技术与装备市场,2003,8(4):47～48.
[25]艾枫.一种新颖的超声振动加工技术.制造技术与机床,2007,3:25～27.
[26] Thoe T B,Aspinwall D K,Killey N.Combined ultrasonic and electrical discharge machining of ceramic coated nickel alloy.Journal of Materials Processing Technology,1999,92:323～328.
[27] Rajurkar K P,Wang Z Y,Kuppattan A.Micro removal of ceramic material (Al2O3) in the precision ultrasonic machining.Precision Engineering,1999,23:73～78.
[28] Guzzo P L,Raslan A A,De Mello J D B.Ultrasonic abrasion of quartz crystals.Wear 2003,255:67～77.
[29] Hu P,Zhang J M,Pei ZJ.Modeling of material removal rate in rotary ultrasonic machining: designed experiments.Journal of Material Processing Technology,2002,129:339～344.
[30]邓建新,曲宝键,郭玉和,等.导电Al2O3基陶瓷刀具材料的超声——放电复合加工技术研究.江苏陶瓷,2002,31:1～5.
[31]秦勇,王霖,吴春丽,等.大理石的超声波加工试验研究.新技术新工艺,2001,2:17～19.
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[33]孔庆华,杨志强.超声波加工建筑玻璃小孔的试验研究.机械科学与技术,1996,25(2):15～18.
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