An adaptive ultrasonic impact method for surface layer modification of large-diameter workpieces

Abstract

The application discloses a large-aperture workpiece surface layer modification self-adaptive ultrasonic impact method, and a device used in the method comprises a vertical lathe machining system, a large-aperture workpiece to be machined and a self-adaptive ultrasonic impact modification system. The vertical lathe machining system comprises a rack, a rotary chuck and a three-axis moving mechanism. The rotary chuck is used for mounting the large-aperture workpiece to be machined. The three-axis moving mechanism is located above the rotary chuck. The self-adaptive ultrasonic impact modification system comprises a connecting tool bar, two symmetrically arranged ultrasonic impact tool heads and a double-acting air cylinder. The connecting tool bar is provided with a linear slide rail extending along an X-axis direction. The two ultrasonic impact tool heads are respectively slidably arranged on the linear slide rail through a double-direction sliding block. The two ultrasonic impact tool heads are connected through the double-acting air cylinder. The double-acting air cylinder drives the two ultrasonic impact tool heads to make linear reciprocating motion along the linear slide rail, so that the inner wall of the workpiece is subjected to ultrasonic impact. The workpiece with high inner surface quality is obtained, and the production cost of the workpiece is reduced.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of ultrasonic machining, in particular to a large-aperture workpiece surface layer modification self-adaptive ultrasonic impact device and method. BACKGROUND

[0002] Large-aperture workpieces are important components in large industrial equipment. These parts often need to have high strength, high wear resistance and high toughness, etc. to ensure that they can withstand harsh working conditions. In traditional technology, manufacturing these large-aperture parts requires the use of heat treatment or chemical methods, which not only has high cost, but also is prone to etching and deformation on the surface of the parts during processing, resulting in poor quality of the processed parts and short service life.

[0003] With the development of science and technology and the continuous improvement of material processing technology, new surface modification technologies have been gradually applied in the field of material processing. Among them, surface ultrasonic modification technology is a fast and effective method that can provide convenience for the production of large industrial equipment. However, the existing ultrasonic modification technology has poor accuracy during the tool setting operation before processing, which requires repeated and frequent tool setting, and is prone to uneven stress on the workpiece during processing, resulting in reduced production efficiency and increased production and processing costs. If the above problems are not effectively prevented, it will cause great loss to personnel and economy. SUMMARY

[0004] The purpose of the present application is to provide a large-aperture workpiece surface layer modification self-adaptive ultrasonic impact method, which can improve the quality of the inner surface of the large-aperture workpiece, prolong the service life of the large-aperture workpiece, and reduce the production, processing and use cost of the workpiece.

[0005] To achieve the above purpose, the solution of the present application is: a large-aperture workpiece surface layer modification self-adaptive ultrasonic impact method, which relates to a large-aperture workpiece surface layer modification self-adaptive ultrasonic impact device, the device comprises a vertical lathe machining system, a workpiece to be processed and a self-adaptive ultrasonic impact modification system.

[0006] The vertical lathe machining system comprises a frame, a rotary chuck provided on the frame and a three-axis movement mechanism, the rotary chuck is used to install the workpiece to be processed, the three-axis movement mechanism is located above the rotary chuck, and the three-axis movement mechanism is connected and drives the self-adaptive ultrasonic impact modification system to perform ultrasonic impact on the workpiece to be processed.

[0007] The adaptive ultrasonic impact modification system includes a connecting tool bar, two symmetrically arranged ultrasonic impact tool heads, and a double-acting cylinder. The connecting tool bar is provided with a linear slide rail extending along the X-axis. The two ultrasonic impact tool heads are slidably mounted on the linear slide rail by a bidirectional slider. The two ultrasonic impact tool heads are connected by a double-acting cylinder. The double-acting cylinder drives the two ultrasonic impact tool heads to perform linear reciprocating motion along the linear slide rail, thereby performing ultrasonic impact on the inner wall of the large-diameter workpiece to be processed.

[0008] The method includes the following steps:

[0009] S1: Installation: Install the large-diameter workpiece to be processed on the rotary chuck, and install the adaptive ultrasonic impact device on the three-axis moving mechanism;

[0010] S2: Tool setting: Control the three-axis moving mechanism to drive the adaptive ultrasonic impact modification system to return to its origin, and adjust the adaptive ultrasonic impact modification system to near the upper end face of the inner hole of the large-diameter workpiece to be machined for tool setting; before tool setting, start the double-acting cylinder, the double-acting cylinder drives the ultrasonic impact tool head at both ends to press against the inner wall of the large-diameter workpiece to be machined, set the lathe tool compensation parameters, and then the three-axis moving mechanism drives the adaptive ultrasonic impact modification system to exit this position to complete the tool setting;

[0011] S3: The three-axis drive mechanism drives the adaptive ultrasonic impact modification system back to the tool setting position mentioned above. The ultrasonic impact tool head on one side first presses against the inner wall of the large-diameter workpiece to be processed. Then, the double-acting cylinder is activated. The piston rod of the double-acting cylinder extends and applies a static load radially to the ultrasonic impact tool head, so that the ultrasonic impact tool heads at both ends completely press against the inner wall of the large-diameter workpiece to be processed. The midpoint of the axis of the two symmetrical ultrasonic impact tool heads on both sides is always aligned with the axis of the large-diameter workpiece to be processed.

[0012] S4: Adjust and set the ultrasonic impact parameters of the adaptive ultrasonic impact modification system and the speed and feed parameters of the vertical lathe machining system, and start the feed to perform surface modification on the large-diameter workpiece to be machined from the initial end to the end.

[0013] Furthermore, the ultrasonic impact parameters are: static pressure of 200–1500 N, amplitude of 3–15 μm, frequency of 12–35 kHz, and power of 500–1600 W;

[0014] The vertical lathe machining system has a rotational speed of 10–400 r / min, a linear speed of 0.210 m / s–16.755 m / s, and a feed rate of 0.015–0.3 mm / r.

[0015] The load capacity of the double-acting cylinder is 125N to 2500N.

[0016] Furthermore, the adaptive ultrasonic shock modification system has a tapered tool holder at the upper end of the connecting tool bar, through which the connecting tool bar and the ultrasonic shock tool head are clamped on the three-axis moving mechanism.

[0017] Furthermore, the three-axis moving mechanism includes a Y-axis guide rail mounted on the frame, an X-axis guide rail mounted on the Y-axis guide rail and sliding along the Y-axis guide rail, and a Z-axis guide rail mounted on the X-axis guide rail and sliding along the X-axis guide rail. A lathe spindle is slidably mounted on the Z-axis guide rail, and the lathe spindle is used to connect the adaptive ultrasonic impact modification system.

[0018] Furthermore, the X-axis guide rail, Z-axis guide rail, and lathe spindle are all connected to drive motors and driven by the connected drive motors.

[0019] After adopting the above solution, the beneficial effects of the present invention are as follows:

[0020] 1. Due to the pressure of the double-acting cylinder, the center line of the symmetrical ultrasonic impact head on both sides and the axis of the large-diameter workpiece to be processed always coincide, without affecting the shape and positional accuracy of the part, thus achieving a floating and adjustable function.

[0021] 2. The center line of the symmetrical ultrasonic impact head on both sides always coincides with the axis of the large-diameter workpiece to be processed, which can compensate for the deviation of the axis of the connecting tool holder and the rotary chuck, resulting in high tool setting accuracy and thus reducing the need for frequent tool setting before processing.

[0022] 3. The center line of the symmetrical ultrasonic impact head on both sides always coincides with the axis of the workpiece with large diameter to be processed. It can automatically compensate for the deviation between the axis of the hole to be processed and the center axis of the rotary chuck, reduce the clamping and positioning requirements of the workpiece. For the processing and modification of non-cylindrical outer surface parts with large diameter, this device can perform simple positioning and quick clamping.

[0023] 4. The ultrasonic impact tool heads, which are symmetrically mounted on both sides, can process the workpiece simultaneously to improve processing efficiency; during processing, the force load on the workpiece is symmetrical, which can reduce the deformation of the workpiece; and during processing, no additional bending moment load is generated on the connecting tool holder, which can effectively maintain its original shape and position accuracy.

[0024] 5. After surface modification, plastic deformation is introduced into the surface layer, refining its surface structure. This can effectively reduce its surface roughness while imparting a high amplitude of residual compressive stress to the surface layer, significantly improving the wear resistance of large-diameter workpieces, increasing the hardness of the workpieces, and extending their service life, thereby achieving the goal of cost reduction. Attached Figure Description

[0025] Figure 1 This is a schematic diagram of the structure of an ultrasonic impact device according to an embodiment of the present invention;

[0026] Figure 2 This is a cross-sectional view of an adaptive ultrasonic impact modification system and a workpiece structure according to an embodiment of the present invention;

[0027] Figure 3 This is a front view of an adaptive ultrasonic impact modification system and a workpiece structure according to an embodiment of the present invention;

[0028] Figure 4 yes Figure 3 Enlarged view of a portion of point A in the middle;

[0029] Figure 5 This is a diagram of the adaptive ultrasonic shock modification system before tool setting according to an embodiment of the present invention;

[0030] Figure 6 This is a diagram of the state of an adaptive ultrasonic shock modification system after tool setting according to an embodiment of the present invention;

[0031] Figure 7 This is a schematic diagram of the motion state of an ultrasonic impact tool head according to an embodiment of the present invention.

[0032] Label Explanation:

[0033] 1. Vertical lathe machining system; 11. Machine frame; 12. Rotary chuck; 13. Three-axis traverse mechanism; 131. Y-axis guide rail; 132. X-axis guide rail; 133. Z-axis guide rail; 134. Lathe spindle;

[0034] 2. Large-diameter workpiece to be machined; 3. Adaptive ultrasonic impact modification system; 31. Tapered tool holder; 32. Connecting tool bar; 33. Ultrasonic impact tool head; 34. Double-acting cylinder; 35. Linear slide rail; 36. Bidirectional slider. Detailed Implementation

[0035] The present invention will be described in detail below with reference to the accompanying drawings and specific embodiments.

[0036] This invention provides an adaptive ultrasonic impact method for surface modification of large-diameter workpieces, and relates to an adaptive ultrasonic impact device for surface modification of large-diameter workpieces, such as... Figures 1 to 7 As shown, the device includes a vertical lathe machining system 1, a large-diameter workpiece to be machined 2, and an adaptive ultrasonic impact modification system 3.

[0037] The vertical lathe machining system 1 includes a frame 11, a rotary chuck 12 mounted on the frame 11, and a three-axis moving mechanism 13. The rotary chuck 12 is used to mount the large-diameter workpiece 2 to be machined. The three-axis moving mechanism 13 is located above the rotary chuck 12. The three-axis moving mechanism 13 is connected to and drives the adaptive ultrasonic impact modification system 3 to move closer to or away from the large-diameter workpiece 2 to be machined, so as to perform ultrasonic impact on the large-diameter workpiece 2 to be machined.

[0038] The adaptive ultrasonic impact modification system 3 includes a connecting tool holder 32, two symmetrically arranged ultrasonic impact tool heads 33, and a double-acting cylinder 34. The connecting tool holder 32 is provided with a linear slide rail 35 extending along the X-axis. The two ultrasonic impact tool heads 33 are slidably mounted on the linear slide rail 35 via a bidirectional slider 36. The ultrasonic impact tool heads 33 and the bidirectional slider 36 are fixedly connected by a locking member. The two ultrasonic impact tool heads 33 are connected by the double-acting cylinder 34. The double-acting cylinder 34 drives the two ultrasonic impact tool heads 33 to perform linear reciprocating motion along the linear slide rail 35 to complete the tool setting work and ultrasonic impact on the inner wall of the large-diameter workpiece 2 to be machined.

[0039] Key points such as Figure 2 and 3 As shown, the adaptive ultrasonic impact modification system 3 has a tapered tool holder 31 at the upper end of the connecting tool holder 32. The upper and lower ends of the tapered tool holder 31 are respectively connected to the three-axis moving mechanism 13 and the connecting tool holder 32, thereby clamping the connecting tool holder 32 and the ultrasonic impact tool head 33 on the three-axis moving mechanism 13. That is, the adaptive ultrasonic impact modification system 3 is clamped on the three-axis moving mechanism 13 of the vertical lathe machining system 1 and is driven to move by the three-axis moving mechanism 13.

[0040] like Figure 1 As shown, the three-axis moving mechanism 13 includes a Y-axis guide rail 131 mounted on the frame 11, an X-axis guide rail 132 mounted on and sliding along the Y-axis guide rail 131, and a Z-axis guide rail 133 mounted on and sliding along the X-axis guide rail 132. A lathe spindle 134 is slidably mounted on the Z-axis guide rail 133, and the lathe spindle 134 is used to connect the adaptive ultrasonic impact modification system 3. The X-axis guide rail (132), Z-axis guide rail (133), and lathe spindle (134) are all connected to drive motors and driven by the connected drive motors.

[0041] The adaptive ultrasonic impact method for surface modification of large-diameter workpieces includes the following steps:

[0042] S1: Installation: Install the large-diameter workpiece 2 to be processed on the rotary chuck 12, and install the adaptive ultrasonic impact modification system 3 on the three-axis moving mechanism 13;

[0043] S2: Tool setting: Control the three-axis moving mechanism 13 to drive the adaptive ultrasonic impact modification system 3 to return to the origin, and adjust the adaptive ultrasonic impact modification system 3 to near the upper end face of the inner hole of the large-diameter workpiece 2 to be machined for tool setting; before tool setting, start the double-acting cylinder 34, the double-acting cylinder 34 drives the ultrasonic impact tool head 33 at both ends to abut against the inner wall of the large-diameter workpiece 2 to be machined, set the lathe tool compensation parameters, and then the three-axis moving mechanism 13 drives the adaptive ultrasonic impact modification system 3 to exit this position to complete the tool setting;

[0044] S3: The three-axis drive mechanism drives the adaptive ultrasonic impact modification system 3 back to the above-mentioned tool setting position. The ultrasonic impact tool head 33 on one side first presses against the inner wall of the large-diameter workpiece 2 to be processed. Then, the double-acting cylinder 34 is activated. The piston rod of the double-acting cylinder 34 extends and applies a static load radially to the ultrasonic impact tool head 33, so that the ultrasonic impact tool heads 33 at both ends completely press against the inner wall of the large-diameter workpiece 2 to be processed.

[0045] S4: Adjust and set the ultrasonic impact parameters of the adaptive ultrasonic impact modification system 3 and the rotational speed and feed rate parameters of the vertical lathe machining system 1. The relevant ultrasonic impact parameters are: static pressure 200-1500N, amplitude 3-15μm, frequency 12-35kHz, and power 500-1600W; rotational speed of the vertical lathe machining system 1 is 10-400r / min, linear speed is 0.210m / s-16.755m / s, and feed rate is 0.015-0.3mm / r; the load of the double-acting cylinder 34 is 125N-2500N. Then, start the feed to perform surface modification on the large-diameter workpiece 2 from the initial end to the end. The adaptive ultrasonic impact modification system allows adjustment of the ultrasonic impact frequency, energy, amplitude, and other process parameters, subsequently obtaining different residual compressive stresses on the inner surface of the workpiece.

[0046] In step S3 of this implementation, before processing, such as Figure 5 As shown, the ultrasonic impact tool head 33 at the right end first abuts against the inner wall of the workpiece. At this time, the axes of the connecting tool bar 32 and the large-diameter workpiece 2 to be processed do not coincide. Then, the double-acting cylinder 34 is driven to extend its piston rod and apply a radial static load to the ultrasonic impact tool head 33, thereby causing the ultrasonic impact tool heads 33 at both ends to abut against both sides of the inner wall of the workpiece (e.g., Figure 6 (As shown). During the processing, due to the pressure of the double-acting cylinder 34, the center line of the symmetrical ultrasonic impact head on both sides and the axis of the large-diameter workpiece 2 to be processed always coincide, without affecting the shape and positional accuracy of the part, thus achieving a floating and adjustable function. This ensures that the large-diameter workpiece 2 to be processed is subjected to good force during the processing and can improve processing efficiency.

[0047] After modification using the above methods, plastic deformation is introduced into the surface layer of the workpiece, refining its surface microstructure. This effectively reduces surface roughness while imparting a high amplitude of residual compressive stress to the workpiece surface, significantly improving the wear resistance of large-diameter workpieces, increasing their hardness, and extending their service life, thereby achieving the goal of cost reduction. Figure 4 As shown, point B represents the surface material state before ultrasonic impact modification, and point C represents the surface material state after ultrasonic impact modification.

[0048] To further illustrate the various embodiments, the present invention provides accompanying drawings. These drawings are part of the disclosure of the present invention, primarily used to illustrate the embodiments and to explain the operating principles of the embodiments in conjunction with the relevant descriptions in the specification. With reference to these drawings, those skilled in the art should be able to understand other possible implementations and the advantages of the present invention. Components in the drawings are not drawn to scale, and similar component symbols are generally used to represent similar components.

[0049] Furthermore, the directions such as front, back, left, and right mentioned in this embodiment are only for reference and do not represent the actual directions in use. In addition, the terms "first," "second," and "third" are used for descriptive purposes only and should not be construed as indicating or implying relative importance.

[0050] The above description is only a preferred embodiment of the present invention and is not intended to limit the design of this case. All equivalent changes made based on the key design features of this case shall fall within the protection scope of this case.

Claims

1. An adaptive ultrasonic impact method for surface modification of large-diameter workpieces, characterized in that: An adaptive ultrasonic impact device for surface modification of large-diameter workpieces is used. The adaptive ultrasonic impact device for surface modification of large-diameter workpieces includes a vertical lathe machining system (1), a large-diameter workpiece to be processed (2), and an adaptive ultrasonic impact modification system (3). The vertical lathe machining system (1) includes a frame (11), a rotary chuck (12) mounted on the frame (11), and a three-axis moving mechanism (13). The rotary chuck (12) is used to mount the large-diameter workpiece (2) to be machined. The three-axis moving mechanism (13) is located above the rotary chuck (12). The three-axis moving mechanism (13) is connected to and drives the adaptive ultrasonic impact modification system (3) to perform ultrasonic impact on the large-diameter workpiece (2) to be machined. The adaptive ultrasonic impact modification system (3) includes a connecting tool bar (32), two symmetrically arranged ultrasonic impact tool heads (33) and a double-acting cylinder (34). The connecting tool bar (32) is provided with a linear slide rail (35) extending along the X-axis. The two ultrasonic impact tool heads (33) are slidably arranged on the linear slide rail (35) by a bidirectional slider (36). The two ultrasonic impact tool heads (33) are connected by a double-acting cylinder (34). The double-acting cylinder (34) drives the two ultrasonic impact tool heads (33) to perform linear reciprocating motion along the linear slide rail (35) to perform ultrasonic impact on the inner wall of the large-diameter workpiece (2) to be processed. The method includes the following steps: S1: Installation: Install the large-diameter workpiece (2) to be processed on the rotary chuck (12), and install the adaptive ultrasonic impact modification system (3) on the three-axis moving mechanism (13); S2: Tool setting: Control the three-axis moving mechanism (13) to drive the adaptive ultrasonic impact modification system (3) to return to the origin and adjust the adaptive ultrasonic impact modification system (3) to the vicinity of the upper end face of the inner hole of the large-diameter workpiece (2) to be machined for tool setting; before tool setting, start the double-acting cylinder (34), the double-acting cylinder (34) drives the ultrasonic impact tool head (33) at both ends to press against the inner wall of the large-diameter workpiece (2) to be machined, set the lathe tool compensation parameters, and then the three-axis moving mechanism (13) drives the adaptive ultrasonic impact modification system (3) to exit this position to complete the tool setting; S3: The three-axis drive mechanism drives the adaptive ultrasonic impact modification system (3) back to the above tool setting position. The ultrasonic impact tool head (33) on one side first presses against the inner wall of the large-diameter workpiece (2) to be processed. Then, the double-acting cylinder (34) is started. The piston rod of the double-acting cylinder (34) extends and applies a static load radially to the ultrasonic impact tool head (33), so that the ultrasonic impact tool heads (33) at both ends completely press against the inner wall of the large-diameter workpiece (2) to be processed. The midpoint of the axis of the symmetrical ultrasonic impact tool heads (33) on both sides and the axis of the large-diameter workpiece (2) to be processed are always coincident. S4: Adjust and set the ultrasonic impact parameters of the adaptive ultrasonic impact modification system (3) and the rotation speed and feed parameters of the vertical lathe machining system (1), and start the feed to perform surface modification on the large-diameter workpiece (2) to be machined from the initial end to the end.

2. The adaptive ultrasonic impact method for surface modification of large-diameter workpieces as described in claim 1, characterized in that: The ultrasonic impact parameters mentioned in step S4 are: static pressure of 200-1500N, amplitude of 3-15μm, frequency of 12-35kHz, and power of 500-1600W. The vertical lathe machining system (1) has a rotational speed of 10-400 r / min, a linear speed of 0.210 m / s-16.755 m / s, and a feed rate of 0.015-0.3 mm / r; The load of the double-acting cylinder (34) is 125N to 2500N.

3. The adaptive ultrasonic impact method for surface modification of large-diameter workpieces as described in claim 1, characterized in that: The adaptive ultrasonic shock modification system (3) has a tapered handle (31) at the upper end of the connecting tool bar (32), and the connecting tool bar (32) and the ultrasonic shock tool head (33) are clamped on the three-axis moving mechanism (13) through the tapered handle (31).

4. The adaptive ultrasonic impact method for surface modification of large-diameter workpieces as described in claim 1, characterized in that: The three-axis moving mechanism (13) includes a Y-axis guide rail (131) mounted on the frame (11), an X-axis guide rail (132) mounted on the Y-axis guide rail (131) and sliding along the Y-axis guide rail (131), and a Z-axis guide rail (133) mounted on the X-axis guide rail (132) and sliding along the X-axis guide rail (132). A lathe spindle (134) is slidably mounted on the Z-axis guide rail (133). The lathe spindle (134) is used to connect the adaptive ultrasonic shock modification system (3).

5. The adaptive ultrasonic impact method for surface modification of large-diameter workpieces as described in claim 4, characterized in that: The X-axis guide rail (132), Z-axis guide rail (133) and lathe spindle (134) are all connected to drive motors and driven by the connected drive motors.

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