Ultrasonic straight-edge knife wear testing equipment and method

Abstract

The present invention provides an ultrasonic straight-edge knife wear test device and method, which aims to simulate and study the wear evolution law of the tool in ultrasonic machining. The ultrasonic straight-edge knife wear test device includes: a cutting system, a positioning system, a holding system, a tool system and a testing system. The cutting system outputs linear reciprocating motion to simulate the low-frequency contact cycle between the grid and the tool; the positioning system realizes precise tool alignment to ensure that the tool and the sample are in just contact; the holding system fixes and tensions the sample to maintain stable cutting conditions; the tool system applies high-frequency vibration to the ultrasonic straight-edge knife to simulate the high-frequency vibration cycle in actual ultrasonic machining; the testing system monitors the contact between the tool and the sample in real time and records the wear behavior. The ultrasonic straight-edge knife wear test device truly reveals the tool wear law in the ultrasonic machining environment by simulating the superposition of low-frequency contact cycle and high-frequency vibration cycle, providing strong technical support for improving tool life and performance.

Description

Technical Field

[0001] The present 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] To ensure stable cutting performance over extended periods, a detailed assessment of tool wear is essential. Ultrasonic straight-edge tools are widely used, particularly when machining composite materials such as honeycombs and carbon fiber composite preforms. Their wear resistance and machining performance are crucial, so analyzing their wear performance is crucial.

[0003] Common methods for predicting material properties include repeatedly cutting honeycomb materials on a machine tool to replicate the wear evolution process and using a tensile testing machine. However, these methods all present challenges and limitations. The first traditional approach involves ultrasonic cutting experiments on a machine tool. This method requires multiple cuts of honeycomb material, often involving lengthy cutting experiments to collect data and observe tool changes during use. Furthermore, each experiment requires cutting a large amount of material, resulting in unnecessary waste. Consequently, this method suffers from a waste of time and resources due to the complexity and difficulty of the experiments. Another common approach involves fatigue testing on a tensile testing machine to predict material properties. However, this method can only be performed at a single frequency cycle, without the ability to combine effects, and therefore cannot reflect the wear evolution observed in actual ultrasonic straight-edge tool cutting. This is because real honeycomb ultrasonic machining is subject to the combined effects of high and low cycles: wear on the ultrasonic straight-edge tool caused by the high-frequency cyclic motion generated by ultrasound under long-term load, and wear on the ultrasonic straight-edge tool caused by the low-frequency contact cycle generated by the feed motion.

[0004] It should be noted that the information disclosed in the above background technology section is only used to understand the background of this application, and therefore may include information that does not constitute prior art known to ordinary technicians in this 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 make low-frequency periodic contact with the tool, simulating the contact cycle between the hole grid and the tool in actual ultrasonic machining;

[0009] The positioning system is used to achieve precise tool setting before cutting before the test begins. The test system can realize real-time visualization of contact to ensure 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, as well as the double-cycle superposition effect of the high-frequency vibration cycle and the low-frequency periodic contact;

[0012] A testing system for real-time monitoring of the contact between the ultrasonic straight-edge knife and the sample, recording the wear behavior of the tool specimen, and observing fatigue and breakage of the specimen;

[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 status between the tool and the sample, thereby realizing 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 through 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 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), wherein 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 respectively move along the x-axis, y-axis and z-axis directions to adjust the distance from the ultrasonic straight-edge knife, and the angle slide (6) is connected to the long plate (5) and the short plate (7) up and down.

[0016] Furthermore, 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 connected and fixed to the pressure sensor (12) and the slide (3); the right vertical plate (13) is configured to be 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 includes: an ultrasonic straight-edge knife (16), an amplitude changer and a transducer (17), a tool holder (18) and a pressure plate (19), wherein 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, and the amplitude changer is connected to the ultrasonic straight-edge knife (16); preferably, the material of the ultrasonic straight-edge 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-edge knife wear testing method using the ultrasonic straight-edge knife wear testing device comprises:

[0021] The positioning system enables precise tool setting before cutting before the test begins, and the test system enables real-time visualization of contact, ensuring that the tool and sample are in perfect contact.

[0022] The cutting system outputs linear reciprocating motion to drive the sample to perform low-frequency periodic contact with the ultrasonic straight-edge tool, simulating the contact cycle between the hole grid and the tool 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] The tool system applies high-frequency vibration to the ultrasonic straight-edge tool 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 monitors the contact between the ultrasonic straight-edge knife and the sample in real time, records the wear behavior of the ultrasonic straight-edge knife sample, and observes the fatigue and breakage of the sample.

[0026] Furthermore, the testing process specifically includes:

[0027] Step A: Conduct a tool wear test without ultrasonic application, in which the sample is repeatedly impacted by an ultrasonic straight-edge knife at a certain frequency, which is equivalent to the low-frequency periodic feed motion of the hole grid under actual working conditions. The wear behavior of the ultrasonic straight-edge knife sample is recorded, and the fatigue and damage of the sample are observed;

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

[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-edge knife under different working conditions. By analyzing the effects of low-frequency periodic motion and high-frequency periodic motion on the wear of the ultrasonic straight-edge knife, a comprehensive evaluation of the wear behavior of the ultrasonic straight-edge knife is achieved;

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

[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, and L is the wear condition of the ultrasonic straight-edge tool caused by the low-frequency grid generated by the feed motion and the tool contact cycle. The wear condition W is positively correlated with 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, 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' 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 it takes for the grid to advance one grid, λ1 is the tool's rake angle, and λ2 is the tool's side rake angle. 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 precisely adjusted, equivalent to the time taken to cut one hole at a fixed feed rate under real cutting conditions. The time the sample contacts the ultrasonic straight-edge knife each time is approximately equal to the actual time it takes to cut one hole, simulating 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 dual 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 tool wear and breakage behavior.

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

[0044] The present invention provides an ultrasonic straight-edge knife wear testing device and method, which tests and studies the effects of high and low frequency dual cycles on tool wear, and can effectively overcome the shortcomings of traditional tool wear evolution test experiments. The application of the ultrasonic straight-edge knife wear testing device of the present invention is very beneficial to solving the above-mentioned problems of traditional testing methods. The ultrasonic straight-edge knife wear testing device of the present invention can be equivalent to the wear generated by an actual ultrasonic straight-edge knife during ultrasonic cutting, and provide an accurate and reliable tool wear evolution process. Through the collaboration of the cutting system, positioning system, holding system, testing system and 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-edge knife wear testing device of the present invention can also accurately and reliably explore the effects of the two dual cycles of the contact period between the hole and the ultrasonic straight-edge knife and the ultrasonic straight-edge knife's own vibration period 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-edge knife wear testing 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 in the existing test platform's inability to provide a true and complete equivalent ultrasonic machining environment. Existing tensile testing machines for fatigue testing can only provide alternating loads at one frequency cycle, and cannot reflect the wear evolution law of actual ultrasonic straight-edge 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 carry out and waste time and materials. The method of the present invention only requires the use of ultrasonic straight-edge knife wear testing equipment. The experiment can be completed by studying the wear of the ultrasonic straight-edge knife caused by the high-frequency periodic motion generated by the ultrasound in the actual ultrasonic cutting process 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.

[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 that can illuminate the light bulb at the moment the ultrasonic straight-edge knife contacts the sample, providing higher alignment accuracy, thereby ensuring the accuracy and stability of the tool during use, saving time and cost.

[0049] (4) Explore the combined effects 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 specimen. By comparing the results, the influence of the dual cycle on tool wear and breakage can be determined, 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 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 2 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 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 the angle slide of the 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 of the present invention and its application.

[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 both fixing and coupling or communication.

[0060] It should be understood that the terms "length", "width", "up", "down", "front", "back", "left", "right", "vertical", "horizontal", "top", "bottom", "inside", "outside", etc., indicating the orientation or position relationship, 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 device or element referred to must have a specific orientation, be constructed and operate in a specific orientation, and therefore cannot be understood as limiting the present invention.

[0061] Furthermore, the terms "first" and "second" are used for descriptive purposes only and should not be understood to indicate or imply relative importance or implicitly specify the number of technical features indicated. Thus, a feature defined as "first" or "second" may explicitly or implicitly include one or more of such features. In the description of the embodiments of the present invention, "plurality" means two or more, unless otherwise specifically defined.

[0062] Real honeycomb ultrasonic machining is subject to the combined effects of high and low cycles: the wear of ultrasonic straight-edge cutters caused by the high-frequency cyclical motion of ultrasound under long-term loads, and the wear caused by the low-frequency contact cycles between the grid and the cutter caused by the feed motion. This invention provides an ultrasonic straight-edge cutter wear tester that can accurately and reliably study the effects of the combined high and low cycles on tool wear.

[0063] See Figures 1 to 6 The ultrasonic straight-edge knife wear testing equipment of an 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 grid and the tool in actual ultrasonic machining; a positioning system, which is used to realize the precise tool alignment process before cutting before the test starts, and realize real-time visualization of the contact with the help of the testing system, so that the tool and the sample are just in contact; a holding system, which is used to fix and tension the sample, ensuring 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-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 low-frequency periodic contact; a testing system, which 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. 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 status between the tool and the sample, thereby realizing accurate testing of the tool wear behavior.

[0064] See 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 3 connected to the connecting rod by a pin, and the slide 3 and the slide rail 4 with the slider are connected vertically by bolts. The brushless spindle motor 1 drives the crank to rotate periodically, converts the circular motion into linear motion through the crank-connecting rod mechanism 2, and then drives the slide 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 feeding 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 rate of the ultrasonic straight-edge tool in actual machining, and s is the width of a single grid. Therefore, by adjusting the spindle speed, the reciprocating speed of the slide can be controlled, thereby equivalent to the low-frequency contact period between the tool and the sample caused by the feed motion in the actual cutting process.

[0067] See 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 respectively move along the x, y and z-axis directions 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 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 an open screw configuration is adopted. The angle slide 6 used has a load of 10kg and a stroke of ±20°.

[0068] See 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 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 measuring range of 0-20kg, which 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 Figure 1 and Figure 5In some embodiments, the tool system includes an ultrasonic straight-edge blade 16, a horn and 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 radially aligned with the transducer 17 and prevents longitudinal unrelated vibration of the entire tool via the upper pressure plate 19. The horn is threadedly connected to the tool 16. The ultrasonic straight-edge blade can be made of tungsten carbide, which is conductive.

[0070] See Figure 6 In some embodiments, the testing system includes a bulb 20, a base 21, and a battery 22. These components are connected by wires to detect contact between the ultrasonic straight-edge knife and the sample. Non-conductive sample materials can be rendered conductive by spraying gold powder on their surfaces.

[0071] See 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 enables precise tool setting before cutting before the test begins, and the test system enables real-time visualization of contact, ensuring that the tool and sample are in perfect contact.

[0073] The cutting system outputs linear reciprocating motion to drive the sample to perform low-frequency periodic contact with the ultrasonic straight-edge tool, simulating the contact cycle between the hole grid and the tool 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] The tool system applies high-frequency vibration to the ultrasonic straight-edge tool 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 monitors the contact between the ultrasonic straight-edge knife and the sample in real time, records the wear behavior of the ultrasonic straight-edge knife sample, and observes the fatigue and breakage of the sample.

[0077] In some specific embodiments, the ultrasonic straight-edge knife wear testing 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-edged 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 situation where the light bulb does not light up for a long time, that is, to avoid the situation where the ultrasonic straight-edged knife does not contact the workpiece for a long time. If the light bulb does not light up for a long time, it is necessary to move the positioning system and re-calibrate the tool.

[0079] Step 2: 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. The wear behavior of the tool sample is recorded, and the fatigue and damage of the sample are observed.

[0080] Step 3: During the test, for the tool wear test scheme with ultrasonic application, ultrasonic vibrations (high-frequency periodic motion) are applied to the tool during the test. Parameters such as the frequency and amplitude of the ultrasonic application are recorded and compared with the test results without ultrasonic application. The wear behavior of the tool specimen is recorded, and fatigue and breakage of the tool specimen are observed. By applying high-frequency periodic ultrasonic motion and low-frequency periodic motion, the dual periodic effects are superimposed.

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

[0082] W∝H+L

[0083] Where W represents tool failure, H represents wear on the ultrasonic straight-edge tool caused by high-frequency cyclic motion generated by ultrasound under long-term load, and L represents wear on the ultrasonic straight-edge tool caused by low-frequency grid and tool contact cycles generated by the feed motion. The wear W is positively correlated to the combined effects of high-frequency and low-frequency cycles. Furthermore, the following relationship holds:

[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 velocity 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 it takes for the grid to advance one grid, λ1 is the tool's rake angle, and λ2 is the tool's side rake angle. 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 speed of the brushless motor, the round-trip time of the slide—and, consequently, the contact time interval between the sample and the ultrasonic straight-edge cutter—can be adjusted. This can be used to equate the time required to cut a grid of holes under real-world cutting conditions at a fixed feed rate. Therefore, the time the sample spends in contact with the ultrasonic straight-edge cutter each time is approximately equal to the time it takes to actually cut a grid of holes. By adjusting the tool setting to ensure effective contact between the sample and the ultrasonic straight-edge cutter, the effects of both the low and high contact period between the grid and the ultrasonic straight-edge cutter and the ultrasonic straight-edge cutter's own vibration period on tool wear and breakage can be studied.

[0092] The ultrasonic straight-edge knife wear testing equipment and method of the present invention can realistically and completely simulate the wear evolution law of the tool in the ultrasonic machining environment, effectively overcoming the shortcomings of traditional testing methods. The equipment realizes the wear test of the tool under the joint action of low-frequency contact cycle and 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 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 with and without 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 usage 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 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 consists of a cutting system, a positioning system, a holding system, a testing system, and a tool system. The cutting system provides low-frequency linear reciprocating motion; the positioning system performs tool alignment before cutting; the holding system secures the sample while ensuring consistent tension every time; the tool system provides ultrasonic vibration for cutting; and the testing system monitors the contact between the tool and the sample in real time. The following details the specific structural design of each system.

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

[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 axes respectively to adjust the distance from the ultrasonic straight blade. The x-axis slide (8), y-axis slide (9), and z-axis slide (10) all have an accuracy of ±0.05mm, a load of 50kg, a stroke of 0-500mm, and adopt an open screw arrangement. 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 includes 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 and loaded. 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 includes: a light bulb (20), a base (21) and a battery (22). Figure 6 In order to ensure the contact between the tool (16) and the sample (14), the surface of the sample is sprayed with gold powder and then subjected to conductive treatment. When the tool (16) and the sample (14) are not in contact, the circuit is open. As long as the tool (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 a mobile positioning system, and the contact is visualized through a 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 situation where the light bulb does not light up for a long time, that is, to avoid the situation where the ultrasonic straight blade knife does not contact the workpiece for a long time. If the light bulb does not light up for a long time, it is necessary to move the positioning system and re-calibrate the tool.

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

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

[0105] The above description further details the present invention in conjunction with specific / preferred embodiments, and the specific implementation of the present invention should not be construed as being limited to these descriptions. Persons skilled in the art will appreciate that, without departing from the spirit of the present invention, they may make various substitutions or modifications to the described embodiments, and these substitutions or modifications should be considered to fall within the scope of protection of the present invention. Throughout this specification, reference to terms such as "one embodiment," "some embodiments," "preferred embodiments," "examples," "specific examples," or "some examples" indicates that the specific features, structures, materials, or characteristics described in conjunction with such embodiment or example are included in at least one embodiment or example of the present invention. In this specification, the schematic representations of these terms do not necessarily refer to the same embodiment or example. Furthermore, the specific features, structures, materials, or characteristics described may be combined in any suitable manner in any one or more embodiments or examples. Persons skilled in the art may combine and assemble the different embodiments or examples described in this specification, as well as features of different embodiments or examples, without conflicting opinions. 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 may be made herein without departing from the scope of protection of the patent application.

Claims

1. An ultrasonic straight-edge knife wear testing device, characterized in that: include: The cutting system is used to output linear reciprocating motion to drive the sample to make low-frequency periodic contact with the tool, simulating the contact cycle between the hole grid and the tool in actual ultrasonic machining; The positioning system is used to achieve precise tool setting before cutting before the test begins. The test system can realize real-time visualization of contact to ensure 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, 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 tool sample, and observe the fatigue and breakage of the sample.

2. The ultrasonic straight blade wear testing device according to claim 1, wherein: 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 through 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, wherein: 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-axis, y-axis and z-axis directions respectively to adjust the distance from the ultrasonic straight-edge 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 claim 2, wherein: 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 (3); the right vertical plate (13) is configured to be 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-edge knife wear testing device according to any one of claims 1 to 3, characterized in that: The sample has a thin-walled porous structure and has the material properties of resin-aramid paper-resin.

6. The ultrasonic straight-edge knife wear testing device according to claim 3, wherein: The tool system comprises: an ultrasonic straight-edge 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-edge knife (16).

7. The ultrasonic straight-edge knife wear testing device according to claim 6, wherein: The material of the ultrasonic straight-edge knife is tungsten carbide hard alloy.

8. The ultrasonic straight-edge knife wear testing device according to any one of claims 1 to 4, 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-edge knife (16) is in contact with the sample (14) by its on and off state; when the ultrasonic straight-edge knife (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.

9. The ultrasonic straight-edge knife wear testing device according to claim 8, wherein: Conductive powder is sprayed on the surface of the sample to make it conductive.

10. An ultrasonic straight blade wear testing method using the ultrasonic straight blade wear testing device according to any one of claims 1 to 9, characterized in that: include: The positioning system enables precise tool setting before cutting before the test begins, and the test system enables real-time visualization of contact, ensuring that the tool and sample are in perfect contact. The cutting system outputs linear reciprocating motion to drive the sample to perform low-frequency periodic contact with the ultrasonic straight-edge tool, simulating the contact cycle between the hole grid and the tool 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; The tool system applies high-frequency vibration to the ultrasonic straight-edge tool 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 monitors the contact between the ultrasonic straight-edge knife and the sample in real time, records the wear behavior of the ultrasonic straight-edge knife sample, and observes the fatigue and breakage of the sample.

11. The ultrasonic straight-edge knife wear testing method according to claim 10, wherein: The testing process specifically includes: Step A: Conduct a tool wear test without ultrasonic application, in which the sample is repeatedly impacted by an ultrasonic straight-edge knife at a certain frequency, which is equivalent to the low-frequency periodic feed motion of the hole grid under actual working conditions. The wear behavior of the ultrasonic straight-edge knife sample is recorded, and the fatigue and damage of the sample are observed; Step B, performing a tool wear test with ultrasound applied, applying ultrasonic vibration to the ultrasonic straight-edge knife during the test, i.e., adding high-frequency periodic motion, recording the frequency and amplitude parameters of the applied ultrasound, and comparing the results with the test results without ultrasound application, recording the wear behavior of the ultrasonic straight-edge knife specimen, and observing the fatigue and breakage of the specimen; Step C: After the test, compare the test results of step A and step B to evaluate the failure status of the ultrasonic straight-edge knife under different working conditions. By analyzing the effects of low-frequency periodic motion and high-frequency periodic motion on the wear of the ultrasonic straight-edge knife, a comprehensive evaluation of the wear behavior of the ultrasonic straight-edge knife is achieved.

12. The ultrasonic straight-edge knife wear testing method according to claim 11, wherein: The comparison in step C is used to evaluate the failure of ultrasonic straight blades under different working conditions, using the following indicators: ； in, W Is the tool failure situation, H It is the wear of ultrasonic straight-edge knives caused by high-frequency periodic motion generated by ultrasound under long-term load. L It is the wear of the ultrasonic straight-edge tool caused by the low-frequency grid generated by the feed motion and the tool contact cycle. W Wear is positively correlated to the superposition of high-frequency cycles and low-frequency cycles, 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, and the y direction is the direction perpendicular to the x-axis and the z-axis. V x 、 V y 、 V z The vibration speed of the ultrasonic straight blade in the x, y, and z directions respectively. V ’ x is the velocity of the sample along the x direction.

13. The ultrasonic straight-edge knife wear testing method according to claim 11, wherein: High-frequency periodic motion is expressed by the following formula: ； in, is the high frequency vibration period, A is the amplitude, t It is the time for Kongge to advance one grid. is the rake angle of the tool, is the tool's side rake angle; Low-frequency periodic motion is expressed by the following formula: ； in, is a low-frequency motion cycle, t It is the time for Kongge to advance one grid. s It is the width of one grid.

14. The ultrasonic straight-edge knife wear testing method according to any one of claims 10 to 13, wherein: 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 precisely adjusted, equivalent to the time taken to cut one hole at a fixed feed rate under real cutting conditions. The time the sample contacts the ultrasonic straight-edge knife each time is approximately equal to the actual time it takes to cut one hole, simulating 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 dual 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 tool wear and breakage behavior.

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