Ultrasonic straight-blade cutter wear test equipment and method

Abstract

The invention provides an ultrasonic straight-blade cutter wear test device and method, and aims to simulate and research a wear evolution rule of a cutter in ultrasonic machining. The ultrasonic straight-blade cutter wear test equipment comprises a cutting system, a positioning system, a holding system, a cutter system and a test system. The cutting system outputs linear reciprocating motion to simulate a low-frequency contact period of a hole grid and a cutter; the positioning system achieves accurate tool setting, and it is ensured that a tool is just in contact with a sample piece; the holding system is used for fixing and tensioning the sample piece and maintaining a stable cutting condition; the cutter system applies high-frequency vibration to the ultrasonic straight-edge cutter to simulate a high-frequency vibration period in actual ultrasonic machining; the testing system monitors the contact condition of the cutter and the sample piece in real time and records the abrasion behavior. According to the ultrasonic straight-blade cutter wear test equipment, by simulating the superposition effect of a low-frequency contact period and a high-frequency vibration period, the cutter wear rule in an ultrasonic machining environment is truly revealed, and powerful technical support is provided for prolonging the service life of a cutter and improving the performance of the cutter.

Description

Technical Field

[0001] The invention relates to the technical field of tool wear testing, and in particular to an ultrasonic straight-edge tool wear testing device and method. Background Art

[0002] In order to ensure the stable cutting performance of the tool during long-term work, its wear condition must be evaluated in detail. Ultrasonic straight-edge tools are widely used tools, especially when processing composite materials such as honeycombs and carbon fiber composite preforms, their wear resistance and processing effect are more critical. Therefore, the analysis of their wear performance is of great significance.

[0003] When predicting material properties, commonly used methods include multiple cutting of honeycomb materials on machine tools to reproduce the wear evolution process and using tensile testing machines. However, these methods all have some difficulties and limitations. The first traditional method is to conduct experiments on ultrasonic cutting of honeycomb materials on machine tools. This method requires multiple cutting of honeycomb materials, usually involving long-term cutting experiments to collect data and observe the changes of the tool during use. In addition, since each experiment requires cutting a large amount of material, it will cause unnecessary waste. Therefore, due to the complexity and difficulty of the experiment, this method has the problem of wasting time and resources. Another common method is to use a tensile testing machine to conduct fatigue tests to predict material properties. However, this method can only be performed under one frequency cycle and cannot superimpose the effect, and cannot reflect the wear evolution law in the actual ultrasonic straight blade ultrasonic cutting. Because the real honeycomb ultrasonic machining is subject to the combined action of high and low double cycles: the wear of the ultrasonic straight blade caused by the high-frequency periodic motion generated by the ultrasound under long-term load, and the wear of the ultrasonic straight blade caused by the low-frequency hole grid and the contact cycle of the tool generated by the feed motion.

[0004] It should be noted that the information disclosed in the above background technology section is only used for understanding the background of the present application, and therefore may include information that does not constitute prior art known to ordinary technicians in the field. Summary of the invention

[0005] The main purpose of the present invention is to overcome the defects existing in the above-mentioned background technology and provide an ultrasonic straight-edge knife wear testing device and method.

[0006] To achieve the above object, the present invention adopts the following technical solutions:

[0007] An ultrasonic straight-edge knife wear testing device, comprising:

[0008] The cutting system is used to output linear reciprocating motion to drive the sample to contact the tool periodically at a low frequency, simulating the contact cycle between the hole grid and the tool in actual ultrasonic machining;

[0009] The positioning system is used to realize the precise tool setting process before cutting before the test begins, and the real-time visualization of the contact is realized with the help of the test system, so that the tool and the sample are in contact;

[0010] The holding system is used to fix and tension the sample to ensure the consistency of tension each time to maintain stable cutting conditions;

[0011] The tool system is used to apply high-frequency vibration to the ultrasonic straight-edge knife, simulating the high-frequency vibration cycle of the ultrasonic straight-edge knife in actual ultrasonic machining, and the double-cycle superposition effect of the combined action of the low-frequency periodic contact;

[0012] The test system is used to monitor the contact between the ultrasonic straight-edge knife and the sample in real time, record the wear behavior of the tool sample, and observe the fatigue and breakage of the sample;

[0013] Among them, the cutting system and the positioning system work together through mechanical connection to achieve precise positioning and feeding of the sample; the positioning system cooperates with the holding system to ensure the stability of the sample during the cutting process; the holding system and the testing system cooperate with each other to monitor and adjust the tensioning state of the sample; the testing system is combined with the tool system to provide real-time feedback on the contact state between the tool and the sample, thereby achieving accurate testing of the tool wear behavior.

[0014] Furthermore, the cutting system comprises: a brushless spindle motor (1), a crank-connecting rod mechanism (2) connected to the brushless spindle motor, a slide plate (3) connected to the crank-connecting rod mechanism (2) via a pin, and the slide plate (3) is connected to a slide rail (4) with a slider; wherein the brushless spindle motor drives the crank to rotate periodically, converts the circular motion into linear motion via the crank-connecting rod mechanism, and then drives the slide plate to slide back and forth on the slide rail; wherein the reciprocating speed of the slide plate can be controlled by adjusting the spindle speed, thereby equivalent to the low-frequency contact cycle between the tool and the sample caused by the feed motion in the actual cutting process.

[0015] Furthermore, the positioning system comprises: a long plate (5), an angle slide (6), a short plate (7), an x-axis slide (8), a y-axis slide (9) and a z-axis slide (10); the x-axis slide (8) is connected to the angle slide (6) via the long plate (5); the x-axis slide (8), the y-axis slide (9) and the z-axis slide (10) can move along the x-, y- and z-axis directions respectively to adjust the distance from the ultrasonic straight blade; the angle slide (6) is connected to the long plate (5) and the short plate (7) up and down.

[0016] Furthermore, the holding system comprises: a left vertical plate (11), a pressure sensor (12), a right vertical plate (13), a sample (14) and a holding fixture (15); the left vertical plate (11) is connected and fixed to the pressure sensor (12) and the slide plate (3); the right vertical plate (13) is adjustable to accommodate samples (14) of different sizes; the holding fixture (15) clamps and fixes the sample (14); and the pressure sensor (12) monitors the change of force during the cutting process in real time.

[0017] Furthermore, the sample has a thin-walled porous structure and possesses the material properties of resin-aramid paper-resin.

[0018] Furthermore, the tool system comprises: an ultrasonic straight-blade knife (16), an amplitude changer and a transducer (17), a tool holder (18) and a pressure plate (19); the tool holder (18) is connected to the z-axis slide (10); the tool holder (18) and the transducer (17) are loaded in a radius-matched manner, and the longitudinal irrelevant vibration of the entire tool is avoided by the pressure plate (19) above; the amplitude changer is connected to the ultrasonic straight-blade knife (16); preferably, the material of the ultrasonic straight-blade knife is tungsten carbide.

[0019] Furthermore, the test system comprises: a light bulb (20), a base (21) and a battery (22); the light bulb (20) indicates whether the ultrasonic straight blade (16) is in contact with the sample (14) by its on and off state; when the ultrasonic straight blade (16) is in conductive contact with the sample (14), the circuit is closed, causing the light bulb (20) to light up; when the two are not in contact, the circuit is disconnected, causing the light bulb (20) to go out; the base (21) is used to fix the light bulb, and the battery (22) provides power for the test system; preferably, conductive powder is sprayed on the surface of the sample to make it conductive.

[0020] An ultrasonic straight blade wear testing method using the ultrasonic straight blade wear testing device comprises:

[0021] The positioning system is used to realize the precise tool setting process before cutting before the test begins, and the real-time visualization of the contact is realized with the help of the test system, so that the tool and the sample are in contact exactly;

[0022] The cutting system outputs linear reciprocating motion to drive the sample to periodically contact the ultrasonic straight-edge cutter at a low frequency, simulating the contact cycle between the hole grid and the cutter in actual ultrasonic machining;

[0023] Fix and tension the sample through the holding system to ensure the consistency of tension each time to maintain stable cutting conditions;

[0024] Apply high-frequency vibration to the ultrasonic straight-edge tool through the tool system to simulate the high-frequency vibration cycle of the ultrasonic straight-edge tool in actual ultrasonic machining, as well as the double-cycle superposition effect of the high-frequency vibration cycle and the low-frequency periodic contact.

[0025] The test system is used to monitor the contact between the ultrasonic straight-edge knife and the sample in real time, record the wear behavior of the ultrasonic straight-edge knife sample, and observe the fatigue and breakage of the sample.

[0026] Furthermore, the testing process specifically includes:

[0027] Step A, performing a tool wear test without applying ultrasound, wherein the sample repeatedly collides with the ultrasonic straight-edge knife at a certain frequency to be equivalent to the low-frequency periodic feeding motion of the hole grid under actual working conditions, and at the same time recording the wear behavior of the ultrasonic straight-edge knife sample, and observing the fatigue and breakage of the sample;

[0028] Step B, performing a tool wear test with ultrasound, applying ultrasonic vibration to the ultrasonic straight-edge knife during the test, i.e., adding high-frequency periodic motion, recording the frequency, amplitude and other parameters of the ultrasound, and comparing the results with the test results without ultrasound, recording the wear behavior of the ultrasonic straight-edge knife sample, and observing the fatigue and breakage of the sample;

[0029] Step C, after the test, compare the test results of step A and step B to evaluate the failure status of the ultrasonic straight blade under different working conditions, and achieve a comprehensive evaluation of the wear behavior of the ultrasonic straight blade by analyzing the influence of low-frequency periodic motion and high-frequency periodic motion on the wear of the ultrasonic straight blade;

[0030] Preferably, the comparison in step C is used to evaluate the failure status of the ultrasonic straight blade under different working conditions, using the following indicators for measurement:

[0031] W∝H+L

[0032] Among them, W is the tool failure condition, H is the wear condition of the ultrasonic straight-edge tool caused by the high-frequency periodic motion generated by ultrasound under long-term load, L is the wear condition of the ultrasonic straight-edge tool caused by the low-frequency hole grid and tool contact cycle generated by the feed motion, and the W wear condition is positively correlated to the superposition of the high-frequency cycle and the low-frequency cycle, and has the following relationship:

[0033]

[0034] Among them, the x direction is the feed direction of the tool, the z direction is the vertical direction of the tool, the y direction is the direction perpendicular to the x-axis and the z-axis, and V x 、V y 、V z The vibration speed of the ultrasonic straight blade in the x, y, and z directions, V' x is the moving speed of the sample along the x direction,

[0035] Preferably, the high-frequency periodic motion can be expressed by the following formula:

[0036]

[0037] Among them, f H is the high-frequency vibration period, A is the amplitude, t is the time for the hole grid to advance one grid, λ1 is the forward tilt angle of the tool, and λ2 is the side tilt angle of the tool. Preferably, the low-frequency periodic motion can be expressed by the following formula:

[0038]

[0039] Among them, f L is the low-frequency motion period, t is the time it takes for the grid to advance one grid, and s is the width of one grid.

[0040] Furthermore, the testing process includes:

[0041] By adjusting the rotation speed of the brushless motor to control the round trip time of the slide, the contact time interval between the sample and the ultrasonic straight-edge knife is accurately adjusted, which is equivalent to the time taken to move one hole grid at a fixed feed speed under real cutting conditions; the time each time the sample contacts the ultrasonic straight-edge knife is approximately equal to the actual time of cutting one hole grid, so as to simulate the contact cycle in actual processing;

[0042] By adjusting the tool setting method, effective contact between the sample and the ultrasonic straight edge knife is ensured, so as to study the influence of two low-frequency and high-frequency double cycles, namely the contact period between the hole and the ultrasonic straight edge knife and the vibration period of the ultrasonic straight edge knife itself, on the wear and breakage behavior of the tool.

[0043] The present invention has the following beneficial effects:

[0044] The present invention provides an ultrasonic straight blade knife wear test device and method, which tests and studies the effect of high and low dual cycles on tool wear, and can effectively overcome the shortcomings of traditional tool wear evolution test experiments. The application of the ultrasonic straight blade knife wear test device of the present invention is very beneficial to solving the above-mentioned problems of traditional testing methods. The ultrasonic straight blade knife wear test device of the present invention can be equivalent to the wear generated by the actual ultrasonic straight blade knife ultrasonic cutting, and provide an accurate and reliable tool wear evolution process. Through the cooperation of the cutting system, the positioning system, the holding system, the testing system and the tool system, the working conditions of the tool under the action of high and low frequency dual cycles can be equivalent; at the same time, the ultrasonic straight blade knife wear test device of the present invention can also accurately and reliably explore the influence of the two dual cycles of the contact period between the hole grid and the ultrasonic straight blade knife and the vibration period of the ultrasonic straight blade knife itself on the tool wear and breakage behavior. Therefore, the present invention provides more comprehensive and powerful technical support for material performance prediction and tool design. Furthermore, the ultrasonic straight blade knife wear test device and method provided in the present invention can also overcome the cumbersomeness of traditional tool setting methods.

[0045] Compared with the prior art, the main advantages of the present invention are:

[0046] (1) Fill the gap that the existing test platform cannot provide a true and complete equivalent ultrasonic machining environment. The existing tensile testing machine for fatigue testing can only provide alternating loads under one frequency cycle, which cannot reflect the wear evolution law of the actual ultrasonic straight blade ultrasonic cutting.

[0047] (2) There is no need to conduct experiments on machine tools. The present invention can study the evolution of tool wear under ultrasonic machining conditions in a more economical and environmentally friendly way. The traditional method of cutting materials multiple times has the problem that experiments are difficult to conduct and waste time and materials. The method of the present invention only needs to use ultrasonic straight-edge knife wear test equipment. The wear of the ultrasonic straight-edge knife caused by the high-frequency periodic motion generated by ultrasound in the equivalent actual ultrasonic cutting process under long-term load, and the wear of the ultrasonic straight-edge knife caused by the contact cycle of the low-frequency grid and the tool generated by the feed motion can complete the experiment.

[0048] (3) An efficient tool alignment test method is provided. Traditional tool alignment methods have some limitations and shortcomings, such as low alignment accuracy or cumbersome operation. The present invention provides a fast tool alignment method, which can provide a light bulb prompt at the moment when the ultrasonic straight blade knife and the sample come into contact, providing higher alignment accuracy, thereby ensuring the accuracy and stability of the tool during use, saving time and cost.

[0049] (4) Explore the combined effect of the low-frequency cutting cycle and the high-frequency vibration cycle. This test method applies ultrasonic vibration to the tool during the test, and compares the test results with those without ultrasonic vibration to observe the wear and breakage of the ultrasonic straight-edge knife sample. By comparing the results, the influence of the dual cycle on tool wear and breakage can be obtained, providing more reliable data support for the performance prediction of ultrasonic straight-edge knife ultrasonic cutting.

[0050] In summary, the application of the ultrasonic straight-edge knife wear testing equipment and method of the present invention can be used to study the superposition effect of low cycles and high cycles, realize accurate prediction and evaluation of material properties, and help to further optimize and improve the technology of ultrasonic application in wear enhancement, improve the wear resistance of materials and extend the service life of cutting tools.

[0051] Other beneficial effects of the embodiments of the present invention will be further described below. BRIEF DESCRIPTION OF THE DRAWINGS

[0052] Figure 1 is a schematic diagram of the overall structure of an ultrasonic straight-edge knife wear testing device according to an embodiment of the present invention;

[0053] Figure 2 It is a partial structural schematic diagram of a cutting system, a positioning system and a holding system according to an embodiment of the present invention;

[0054] Figure 3 Schematic diagram of a three-axis mobile platform of a positioning system according to an embodiment of the present invention.

[0055] Figure 4 Schematic diagram of an angle slide of a positioning system according to an embodiment of the present invention

[0056] Figure 5 is a schematic diagram of a tool system according to an embodiment of the present invention;

[0057] Figure 6 is a schematic diagram of a contact testing method according to an embodiment of the present invention; DETAILED DESCRIPTION

[0058] The following is a detailed description of the embodiments of the present invention. It should be emphasized that the following description is only exemplary and is not intended to limit the scope and application of the present invention.

[0059] It should be noted that when an element is referred to as being "fixed to" or "disposed on" another element, it can be directly on the other element or indirectly on the other element. When an element is referred to as being "connected to" another element, it can be directly connected to the other element or indirectly connected to the other element. In addition, connection can be used for fixing as well as for coupling or communication.

[0060] It should be understood that the orientation or position relationship indicated by terms such as "length", "width", "up", "down", "front", "back", "left", "right", "vertical", "horizontal", "top", "bottom", "inside" and "outside" are based on the orientation or position relationship shown in the accompanying drawings, and are only for the convenience of describing the embodiments of the present invention and simplifying the description, and do not indicate or imply that the referred device or element must have a specific orientation, be constructed and operated in a specific orientation, and therefore cannot be understood as a limitation on the present invention.

[0061] In addition, the terms "first" and "second" are used for descriptive purposes only and should not be understood as indicating or implying relative importance or implicitly indicating the number of technical features indicated. Thus, a feature defined as "first" or "second" may explicitly or implicitly include one or more of the features. In the description of the embodiments of the present invention, the meaning of "plurality" is two or more, unless otherwise clearly and specifically defined.

[0062] Real honeycomb ultrasonic machining is affected by the combined effects of high and low cycles: the wear of the ultrasonic straight-edge knife caused by the high-frequency periodic motion generated by ultrasound under long-term load, and the wear of the ultrasonic straight-edge knife caused by the contact cycle between the low-frequency grid and the tool generated by the feed motion. The present invention provides an ultrasonic straight-edge knife wear test device that can accurately and reliably study the influence of the superposition of high and low cycles on tool wear.

[0063] See also Figures 1 to 6 The ultrasonic straight blade wear test equipment of the embodiment of the present invention includes: a cutting system, which is used to output linear reciprocating motion to drive the sample to perform low-frequency periodic contact with the tool, simulating the contact cycle between the hole grid and the tool in actual ultrasonic processing; a positioning system, which is used to realize the precise tool alignment process before cutting before the test starts, and realize the real-time visualization of the contact with the help of the test system, so that the tool and the sample are just in contact; a holding system, which is used to fix and tension the sample to ensure the consistency of the tensioning force each time to maintain stable cutting conditions; a tool system, which is used to apply high-frequency vibration to the ultrasonic straight blade, simulating the high-frequency vibration cycle of the ultrasonic straight blade in actual ultrasonic processing, and the double-cycle superposition effect of the low-frequency periodic contact; a test system, which is used to monitor the contact between the ultrasonic straight blade and the sample in real time, record the wear behavior of the tool sample, and observe the fatigue and breakage of the sample. Among them, the cutting system and the positioning system work together through mechanical connection to achieve precise positioning and feeding of the sample; the positioning system cooperates with the holding system to ensure the stability of the sample during the cutting process; the holding system and the testing system cooperate with each other to monitor and adjust the tensioning state of the sample; the testing system is combined with the tool system to provide real-time feedback on the contact state between the tool and the sample, thereby achieving accurate testing of the tool wear behavior.

[0064] See also Figure 1 and Figure 2 In some embodiments, the cutting system includes a brushless spindle motor 1, a crank-connecting rod mechanism 2 connected to the brushless spindle motor 1, a slide plate 3 connected to the connecting rod through a pin, and the slide plate 3 and the slide rail 4 with a slider are connected up and down by bolts. The brushless spindle motor 1 drives the crank to rotate periodically, and the circular motion is converted into linear motion through the crank-connecting rod mechanism 2, thereby driving the slide plate 3 to slide back and forth on the slide rail 4. The speed of the brushless spindle motor 1 should be consistent with the speed of the low-frequency motion cycle of one grid each time during the actual cutting process. It can be expressed by the following formula:

[0065]

[0066] Where n is the spindle speed of the brushless spindle motor, in r / min. f is the feed speed of the ultrasonic straight-edge tool in actual processing, and s is the width of one grid. Therefore, by adjusting the spindle speed, the reciprocating speed of the slide can be controlled, which can be equivalent to the low-frequency contact cycle between the tool and the sample caused by the feed motion in the actual cutting process.

[0067] See also Figures 1 to 4 In some embodiments, the positioning system includes: a long plate 5, an angle slide 6, a short plate 7, an x-axis slide 8, a y-axis slide 9 and a z-axis slide 10. The x-axis slide 8 is connected to the angle slide 6 through the long plate 5. The x-axis slide 8, the y-axis slide 9 and the z-axis slide 10 can move along the x, y and z-axis directions respectively to adjust the distance from the ultrasonic straight blade knife. The angle slide 6 is connected to the long plate 5 and the short plate 7 up and down by screws. In a specific embodiment, the accuracy of the x-axis slide 8, the y-axis slide 9 and the z-axis slide 10 are all ±0.05mm, the load is 50kg, the stroke is 0-500mm, and the screw open type is adopted. The angle slide 6 used has a load of 10kg and a stroke of ±20°.

[0068] See also Figure 1 , Figure 2 and Figure 6 In some embodiments, the holding system includes: a left vertical plate 11, a pressure sensor 12, a right vertical plate 13, a sample 14 and a holding fixture 15. The left vertical plate 11 is fixed to the pressure sensor 12 and the slide plate 3 by screws, the bottom of the right vertical plate 13 is not fixed, and the holding fixture 15 fixes the sample 14 by rotating the screw clamp. In a specific embodiment, the pressure sensor 12 has an accuracy of 0.02% and a range of 0-20kg, and can monitor the change of force during the cutting process in real time. The sample itself has a thin-walled and porous structure and has the material properties of resin-aramid paper-resin.

[0069] See also Figure 1 and Figure 5In some embodiments, the tool system includes: an ultrasonic straight blade knife 16, a horn and a transducer 17, a tool holder 18 and a pressure plate 19. The tool holder 18 is screwed to the z-axis slide 10. The tool holder 18 is loaded with the transducer 17 in a radius-matched manner, and the longitudinal irrelevant vibration of the tool as a whole is avoided through the upper pressure plate 19. The horn is threadedly connected to the tool 16. The material of the ultrasonic straight blade knife can be tungsten carbide hard alloy, which can conduct electricity.

[0070] See also Figure 6 In some embodiments, the test system includes: a light bulb 20, a base 21 and a battery 22. The components are connected by wires to detect the contact between the ultrasonic straight blade knife and the sample. The non-conductive sample material can be conductive after gold powder is sprayed on the surface.

[0071] See also Figures 1 to 6 The embodiment of the present invention further provides an ultrasonic straight blade wear testing method using the ultrasonic straight blade wear testing device, comprising:

[0072] The positioning system is used to realize the precise tool setting process before cutting before the test begins, and the real-time visualization of the contact is realized with the help of the test system, so that the tool and the sample are in contact exactly;

[0073] The cutting system outputs linear reciprocating motion to drive the sample to periodically contact the ultrasonic straight-edge cutter at a low frequency, simulating the contact cycle between the hole grid and the cutter in actual ultrasonic machining;

[0074] Fix and tension the sample through the holding system to ensure the consistency of tension each time to maintain stable cutting conditions;

[0075] Apply high-frequency vibration to the ultrasonic straight-edge tool through the tool system to simulate the high-frequency vibration cycle of the ultrasonic straight-edge tool in actual ultrasonic machining, as well as the double-cycle superposition effect of the high-frequency vibration cycle and the low-frequency periodic contact.

[0076] The test system is used to monitor the contact between the ultrasonic straight-edge knife and the sample in real time, record the wear behavior of the ultrasonic straight-edge knife sample, and observe the fatigue and breakage of the sample.

[0077] In some specific embodiments, the ultrasonic straight blade wear test method specifically includes the following steps:

[0078] Step 1: Before the test begins, a tool setting test is required to ensure that the tool and the sample are in contact. The specific tool setting test method is as follows: The contact between the tool and the sample is achieved through a mobile positioning system, and the real-time visualization of the contact is achieved through a test system: The material of the ultrasonic straight blade knife is generally tungsten carbide, which can conduct electricity, and the sample is not conductive. It can conduct electricity after spraying gold powder on the surface. When the tool and the sample are not in contact, the circuit is open. As long as the tool and the sample are in contact, the circuit will become open and the light bulb will light up to prompt. In addition, observe the brightness of the light bulb during the test to avoid the light bulb not being lit for a long time, that is, to avoid the ultrasonic straight blade knife and the workpiece not being in contact for a long time. If the light bulb does not light up for a long time, the positioning system needs to be moved to re-calibrate the tool.

[0079] Step 2: During the test, for the tool wear test scheme without applying ultrasound, the sample is repeatedly collided with the tool at a certain frequency for multiple times to be equivalent to the low-frequency periodic feed motion of the hole grid under actual working conditions, and the wear behavior of the tool sample is recorded, and the fatigue and breakage of the sample are observed.

[0080] Step 3: During the test, for the tool wear test scheme with ultrasonic application, ultrasonic vibration is applied to the tool during the test, that is, high-frequency periodic motion is added, and the frequency, amplitude and other parameters of the ultrasonic application are recorded, and compared with the test results without ultrasonic application, the wear behavior of the tool sample is recorded, and the fatigue and breakage of the tool sample are observed. The superposition of the dual-periodic action is achieved by applying high-frequency periodic motion ultrasound and low-frequency periodic motion feeding.

[0081] Step 4: After the test, compare the results of the two test schemes to evaluate the failure of the ultrasonic straight blade under different working conditions. The following indicators can be used to measure:

[0082] W∝H+L

[0083] Among them, W is the tool failure condition, H is the wear condition of the ultrasonic straight-edge tool caused by the high-frequency periodic motion generated by ultrasound under long-term load, and L is the wear condition of the ultrasonic straight-edge tool caused by the low-frequency grid and tool contact cycle generated by the feed motion. The wear condition W is positively correlated to the superposition of the high-frequency cycle and the low-frequency cycle. In addition, there is the following relationship:

[0084]

[0085] Among them, the x direction is the feed direction of the tool, the z direction is the vertical direction of the tool, and the y direction is the direction perpendicular to the x-axis and the z-axis. x 、V y 、V z The vibration speed of the ultrasonic straight blade in the x, y, and z directions, V' xis the moving speed of the sample along the x direction.

[0086] Preferably, the high-frequency periodic motion can be expressed by the following formula:

[0087]

[0088] Among them, f H is the high-frequency vibration period, A is the amplitude, t is the time for the hole grid to advance one grid, λ1 is the front tilt angle of the tool, and λ2 is the side tilt angle of the tool. Preferably, the low-frequency periodic motion can be expressed by the following formula:

[0089]

[0090] Among them, f L is the low-frequency motion period, t is the time it takes for the grid to advance one grid, and s is the width of one grid.

[0091] By adjusting the rotation speed of the brushless motor, the round trip time of the slide can be adjusted, that is, the contact time interval between the sample and the ultrasonic straight blade can be adjusted, which can be equivalent to the actual cutting condition: the time taken to cut a hole at a fixed feed rate. Therefore, the time each time the sample contacts the ultrasonic straight blade can be approximately equal to the actual time to cut a hole. By adjusting the tool setting method to ensure effective contact between the sample and the ultrasonic straight blade, the influence of the two low and high double cycles of the contact period between the hole and the ultrasonic straight blade and the vibration period of the ultrasonic straight blade itself on the tool wear and breakage behavior can be studied.

[0092] The ultrasonic straight-edge knife wear test equipment and method of the present invention can truly and completely simulate the wear evolution law of the tool under the ultrasonic machining environment, effectively overcoming the shortcomings of the traditional test method. The equipment realizes the wear test of the tool under the combined action of the low-frequency contact cycle and the high-frequency vibration cycle, providing an economical, environmentally friendly and efficient testing platform, without the need to conduct actual cutting experiments on the machine tool, reducing material waste and experimental time. In addition, the embodiment of the present invention also provides an efficient tool alignment test method, which can realize rapid tool alignment through the light bulb light prompt at the moment of contact between the tool and the sample, improve the alignment accuracy, and ensure the accuracy and stability of the tool during use. By comparing the test results of applying ultrasonic vibration and not applying ultrasonic vibration, the present invention can explore the influence of the double cycle on tool wear and breakage, and provide reliable data support for the performance prediction of ultrasonic straight-edge knives, thereby helping to optimize and improve ultrasonic machining technology, improve the wear resistance of materials and extend the service life of tools.

[0093] Examples

[0094] like Figures 1 to 5This example provides a structure and use method of an orthogonal cutting micro-scale in-situ observation device, including a brushless spindle motor 1 of a cutting system, a crank-connecting rod mechanism 2, a slide plate 3, a slide rail 4, a long plate 5, an angle slide 6, a short plate 7, an x-axis slide 8, a y-axis slide 9, a z-axis slide 10, a left vertical plate 11, a sensor 12, a right vertical plate 13, a sample 14, a holding plate 15, a tool 16, a transducer 17, a tool holder 18, a pressure plate 19, a light bulb 20, a base 21 and a battery 22.

[0095] Figure 1 The overall structure diagram of the ultrasonic straight blade wear testing device according to the embodiment of the present invention is shown in FIG. Figure 1 The test bench includes a cutting system, a positioning system, a holding system, a testing system and a tool system; the cutting system is used to provide low-frequency linear reciprocating motion; the positioning system is used to perform tool setting before cutting; the holding system is used to fix the sample and ensure that the tension is consistent each time; the tool system is used to provide ultrasonic vibration cutting; and the testing system is used to monitor the contact between the tool and the sample in real time. The specific structural design of each system is introduced in detail below.

[0096] In one embodiment, see Figure 2 The brushless motor (1) of the cutting system drives the crank (2) to rotate periodically, and the circular motion is converted into linear motion through the crank connecting rod mechanism, thereby driving the slide plate (3) to slide back and forth on the slide rail (4). The angle slide table (6) is mainly used for fine adjustment of the deflection during the experiment, and can also be used to adjust the contact angle between the sample and the ultrasonic straight blade.

[0097] In this embodiment, see Figure 2 The holding plate (15) clamps the sample (14) by rotating the screw, the bottom of the left vertical plate (11) is fixed, and the middle is connected to the sensor (12), and the right vertical plate (13) is not fixed, so that the sensor (12) can record the tension force of each clamping of the sample (14).

[0098] In this embodiment, see Figure 3 and Figure 4 , the x-axis slide (8), y-axis slide (9), and z-axis slide (10) can move along the x-, y-, and z-axis directions respectively to adjust the distance from the ultrasonic straight blade knife. The x-axis slide (8), y-axis slide (9), and z-axis slide (10) have an accuracy of ±0.05mm, a load of 50kg, a stroke of 0-500mm, and adopt a screw open type. The angle slide (6) used has a load of 10kg and a stroke of ±20° to achieve high-precision tool setting.

[0099] In this embodiment, see Figure 5The tool system comprises a tool (16), a transducer (17) and a tool holder (18). The tool holder (18) is bolted to the z-axis slide (10). The tool holder (18) and the transducer (17) are radially matched for loading. The tool holder (18) is threadedly connected to the pressure plate (19). The transducer (17) is threadedly connected to the tool (16). The z-axis slide (10) can be used to move the tool up and down to approach the sample (14).

[0100] In this embodiment, see Figure 2 The test system comprises: a light bulb (20), a base (21) and a battery (22). Figure 6 In order to ensure the contact between the cutter (16) and the sample (14), the surface of the sample is sprayed with gold powder and then subjected to conductive treatment. When the cutter (16) and the sample (14) are not in contact, the circuit is open. As long as the cutter (16) and the sample (14) are in contact, the circuit becomes open and the light bulb (20) will light up.

[0101] The ultrasonic straight edge knife wear test method using the above test equipment includes:

[0102] Before the test begins, a tool setting test is required to ensure that the tool and the sample are in contact. The specific tool setting test method is as follows: the contact between the tool and the sample is achieved through the mobile positioning system, and the contact is visualized through the test system: the material of the ultrasonic straight blade knife is generally tungsten carbide, which can conduct electricity, and the aramid paper sample is not conductive. It can conduct electricity after spraying gold powder on the surface. When the tool and the sample are not in contact, the circuit is open. As long as the tool and the sample are in contact, the circuit will become open and the light bulb will light up to prompt. In addition, observe the brightness of the light bulb during the test to avoid the light bulb not being lit for a long time, that is, to avoid the ultrasonic straight blade knife and the workpiece not being in contact for a long time. If the light bulb does not light up for a long time, the positioning system needs to be moved to re-calibrate the tool.

[0103] During the test, for the tool wear test scheme without applying ultrasound, the sample repeatedly collides with the tool at a certain frequency to be equivalent to the low-frequency periodic feed motion of the hole grid under actual working conditions, and the wear behavior of the tool sample is recorded, and the fatigue and breakage of the sample are observed. For the tool wear test scheme with ultrasound, ultrasonic vibration is applied to the tool during the test, that is, high-frequency periodic motion is added, and the frequency, amplitude and other parameters of the ultrasound are recorded, and compared with the test results without applying ultrasound, the wear behavior of the tool sample is recorded, and the fatigue and breakage of the tool sample is observed. The superposition of dual-periodic effects is achieved by applying ultrasound with high-frequency periodic motion and feeding with low-frequency periodic motion.

[0104] In summary, in view of the defect that the traditional wear evolution test method cannot fully and efficiently reflect the ultrasonic processing of fiber-reinforced composite materials, the present invention proposes an ultrasonic straight blade knife wear test device and method. This test equipment can be equivalent to the wear evolution law in the actual ultrasonic straight blade knife cutting, and study the influence of the double cycle on the tool wear behavior: the low-frequency contact period between the hole and the ultrasonic straight blade knife and the high-frequency vibration period of the ultrasonic straight blade knife itself. The cutting system outputs linear reciprocating motion, driving the sample to contact the tool at a low frequency periodicity. At the same time, the ultrasonic straight blade knife is applied with high-frequency vibration through the tool system, which directly equals the superposition effect of the double cycle of ultrasonic straight blade knife wear test. Through the present invention, it is possible to accurately and reliably explore the common effects of low-frequency contact cycle and high-frequency vibration cycle on tool wear, truly and accurately reveal the tool wear law under ultrasonic processing environment, and provide strong technical support for improving the life and performance of the tool.

[0105] The above content is a further detailed description of the present invention in combination with specific / preferred embodiments, and it cannot be determined that the specific implementation of the present invention is limited to these descriptions. For ordinary technicians in the technical field to which the present invention belongs, without departing from the concept of the present invention, it can also make several substitutions or modifications to these described embodiments, and these substitutions or modifications should be regarded as belonging to the protection scope of the present invention. In the description of this specification, the description of the reference terms "an embodiment", "some embodiments", "preferred embodiments", "examples", "specific examples", or "some examples" means that the specific features, structures, materials or characteristics described in combination with the embodiment or example are included in at least one embodiment or example of the present invention. In this specification, the schematic representation of the above terms does not necessarily target the same embodiment or example. Moreover, the specific features, structures, materials or characteristics described can be combined in any one or more embodiments or examples in a suitable manner. In the absence of mutual contradiction, those skilled in the art can combine and combine the different embodiments or examples described in this specification and the features of different embodiments or examples. Although the embodiments of the present invention and their advantages have been described in detail, it should be understood that various changes, substitutions and modifications can be made herein without departing from the scope of protection of the patent application.

Claims

1. An ultrasonic straight blade wear testing device, characterized in that: include: The cutting system is used to output linear reciprocating motion to drive the sample to contact the tool periodically at a low frequency, simulating the contact cycle between the hole grid and the tool in actual ultrasonic machining; The positioning system is used to realize the precise tool setting process before cutting before the test begins, and the real-time visualization of the contact is realized with the help of the test system, so that the tool and the sample are in contact; The holding system is used to fix and tension the sample to ensure the consistency of tension each time to maintain stable cutting conditions; The tool system is used to apply high-frequency vibration to the ultrasonic straight-edge knife, simulating the high-frequency vibration cycle of the ultrasonic straight-edge knife in actual ultrasonic machining, and the double-cycle superposition effect of the combined action of the low-frequency periodic contact; The test system is used to monitor the contact between the ultrasonic straight-edge knife and the sample in real time, record the wear behavior of the tool sample, and observe the fatigue and breakage of the sample.

2. The ultrasonic straight blade wear testing device according to claim 1, characterized in that: The cutting system comprises: a brushless spindle motor (1), a crank-connecting rod mechanism (2) connected to the brushless spindle motor, a slide plate (3) connected to the crank-connecting rod mechanism (2) via a pin, and the slide plate (3) is connected to a slide rail (4) with a slider; wherein the brushless spindle motor drives the crank to rotate periodically, converts the circular motion into linear motion via the crank-connecting rod mechanism, and then drives the slide plate to slide back and forth on the slide rail; wherein the reciprocating speed of the slide plate can be controlled by adjusting the spindle speed, thereby equivalent to the low-frequency contact cycle between the tool and the sample caused by the feed motion in the actual cutting process.

3. The ultrasonic straight blade wear testing device according to claim 1 or 2, characterized in that: The positioning system comprises: a long plate (5), an angle slide (6), a short plate (7), an x-axis slide (8), a y-axis slide (9) and a z-axis slide (10); the x-axis slide (8) is connected to the angle slide (6) via the long plate (5); the x-axis slide (8), the y-axis slide (9) and the z-axis slide (10) can move along the x-, y- and z-axis directions respectively to adjust the distance from the ultrasonic straight-blade knife; the angle slide (6) is connected to the long plate (5) and the short plate (7) up and down.

4. The ultrasonic straight blade wear testing device according to any one of claims 1 to 3, characterized in that: The holding system comprises: a left vertical plate (11), a pressure sensor (12), a right vertical plate (13), a sample (14) and a holding fixture (15); the left vertical plate (11) is connected and fixed to the pressure sensor (12) and the slide plate (3); the right vertical plate (13) is adjustable to accommodate samples (14) of different sizes; the holding fixture (15) clamps and fixes the sample (14); and the pressure sensor (12) monitors the change of force during the cutting process in real time.

5. The ultrasonic straight blade wear testing device according to any one of claims 1 to 3, characterized in that: The sample has a thin-walled porous structure and possesses the material properties of resin-aramid paper-resin.

6. The ultrasonic straight blade wear testing device according to claim 3, characterized in that: The tool system comprises: an ultrasonic straight-blade knife (16), an amplitude changer and a transducer (17), a tool holder (18) and a pressure plate (19); the tool holder (18) is connected to the z-axis slide (10); the tool holder (18) and the transducer (17) are loaded in a radius-matched manner, and the longitudinal irrelevant vibration of the entire tool is avoided through the pressure plate (19) above; the amplitude changer is connected to the ultrasonic straight-blade knife (16); preferably, the material of the ultrasonic straight-blade knife is tungsten carbide.

7. The ultrasonic straight blade wear testing device according to any one of claims 1 to 6, characterized in that: The test system comprises: a light bulb (20), a base (21) and a battery (22); the light bulb (20) indicates whether the ultrasonic straight blade (16) is in contact with the sample (14) by its on and off state; when the ultrasonic straight blade (16) is in conductive contact with the sample (14), the circuit is closed, causing the light bulb (20) to light up; when the two are not in contact, the circuit is disconnected, causing the light bulb (20) to go out; the base (21) is used to fix the light bulb, and the battery (22) provides power for the test system; preferably, conductive powder is sprayed on the surface of the sample to make it conductive.

8. An ultrasonic straight blade wear testing method using the ultrasonic straight blade wear testing device according to any one of claims 1 to 7, characterized in that: include: The positioning system is used to realize the precise tool setting process before cutting before the test begins, and the real-time visualization of the contact is realized with the help of the test system, so that the tool and the sample are in contact exactly; The cutting system outputs linear reciprocating motion to drive the sample to periodically contact the ultrasonic straight-edge cutter at a low frequency, simulating the contact cycle between the hole grid and the cutter in actual ultrasonic machining; Fix and tension the sample through the holding system to ensure the consistency of tension each time to maintain stable cutting conditions; Apply high-frequency vibration to the ultrasonic straight-edge tool through the tool system to simulate the high-frequency vibration cycle of the ultrasonic straight-edge tool in actual ultrasonic machining, as well as the double-cycle superposition effect of the high-frequency vibration cycle and the low-frequency periodic contact. The test system is used to monitor the contact between the ultrasonic straight-edge knife and the sample in real time, record the wear behavior of the ultrasonic straight-edge knife sample, and observe the fatigue and breakage of the sample.

9. The ultrasonic straight blade wear testing method according to claim 8, characterized in that: The testing process specifically includes: Step A, performing a tool wear test without applying ultrasound, wherein the sample repeatedly collides with the ultrasonic straight-edge knife at a certain frequency to be equivalent to the low-frequency periodic feeding motion of the hole grid under actual working conditions, and at the same time recording the wear behavior of the ultrasonic straight-edge knife sample, and observing the fatigue and breakage of the sample; Step B, performing a tool wear test with ultrasound, applying ultrasonic vibration to the ultrasonic straight-edge knife during the test, i.e., adding high-frequency periodic motion, recording the frequency, amplitude and other parameters of the ultrasound, and comparing the results with the test results without ultrasound, recording the wear behavior of the ultrasonic straight-edge knife sample, and observing the fatigue and breakage of the sample; Step C, after the test, compare the test results of step A and step B to evaluate the failure status of the ultrasonic straight blade under different working conditions, and achieve a comprehensive evaluation of the wear behavior of the ultrasonic straight blade by analyzing the influence of low-frequency periodic motion and high-frequency periodic motion on the wear of the ultrasonic straight blade; Preferably, the comparison in step C is used to evaluate the failure status of the ultrasonic straight blade under different working conditions, using the following indicators for measurement: W∝H+L Among them, W is the tool failure condition, H is the wear condition of the ultrasonic straight-edge tool caused by the high-frequency periodic motion generated by ultrasound under long-term load, L is the wear condition of the ultrasonic straight-edge tool caused by the low-frequency hole grid and tool contact cycle generated by the feed motion, and the W wear condition is positively correlated to the superposition of the high-frequency cycle and the low-frequency cycle, and has the following relationship: Among them, the x direction is the feed direction of the tool, the z direction is the vertical direction of the tool, the y direction is the direction perpendicular to the x-axis and the z-axis, and V x 、V y 、V z The vibration speed of the ultrasonic straight blade in the x, y, and z directions, V' x is the moving speed of the sample along the x direction, Preferably, the high-frequency periodic motion can be expressed by the following formula: Among them, f H is the high-frequency vibration period, A is the amplitude, t is the time for the hole grid to advance one grid, λ1 is the forward tilt angle of the tool, and λ2 is the side tilt angle of the tool. Preferably, the low-frequency periodic motion can be expressed by the following formula: Among them, f L is the low-frequency motion period, t is the time it takes for the grid to advance one grid, and s is the width of one grid.

10. The ultrasonic straight blade wear testing method according to claim 8 or 9, characterized in that: The testing process includes: By adjusting the rotation speed of the brushless motor to control the round trip time of the slide, the contact time interval between the sample and the ultrasonic straight-edge knife is accurately adjusted, which is equivalent to the time taken to move one hole grid at a fixed feed speed under real cutting conditions; the time each time the sample contacts the ultrasonic straight-edge knife is approximately equal to the actual time of cutting one hole grid, so as to simulate the contact cycle in actual processing; By adjusting the tool setting method, effective contact between the sample and the ultrasonic straight edge knife is ensured, so as to study the influence of two low-frequency and high-frequency double cycles, namely the contact period between the hole and the ultrasonic straight edge knife and the vibration period of the ultrasonic straight edge knife itself, on the wear and breakage behavior of the tool.

Images