A laser-ultrasonic collaborative texturing tool dynamic clearance heat dissipation composite machining device and method

Abstract

The present invention belongs to the field of composite machining, and specifically discloses a laser-ultrasonic collaborative texture tool dynamic clearance heat dissipation composite machining device and method, including designing the surface micro-texture parameters of the tool according to the material and shape characteristics of the parts to be machined; clamping the tool on the ultrasonic vibration-assisted machining device to accurately position the tool at the micro-texture preparation station, and using the femtosecond laser of the laser machining composite device to prepare micro-textures on the tool surface; clamping the workpiece, installing the micro-texture tool on the ultrasonic vibration-assisted machining device, positioning the micro-texture tool at the composite machining station and completing tool setting, the laser machining composite device and the ultrasonic vibration-assisted machining device move synchronously, adjusting the laser machining composite device to make the auxiliary heating laser beam preheat and soften the area to be machined and inhibit thermal damage, and the ultrasonic vibration-assisted machining device makes the micro-texture tool perform ultrasonic vibration to achieve periodic intermittent machining, and perform the machining feed process to complete the composite machining.

Description

Technical Field

[0001] The present invention belongs to the field of hybrid machining in non-traditional machining technologies, and specifically discloses a laser-ultrasonic collaborative texturing tool dynamic clearance heat dissipation hybrid machining device and method. Background Art

[0002] During high-quality and high-efficiency machining, material removal is regarded as a complex system with multiple input and output variables, involving the evolution of surface and interface contact behaviors such as force, heat, chemistry, and materials that interact with each other. Currently, there are many processing methods that directly or indirectly change the interface contact conditions to affect the machining behavior, such as laser-assisted machining, ultrasonic vibration-assisted machining, etc.; among them, laser-assisted machining can reduce the cutting force through preheating, but continuous heat input exacerbates tool thermal damage. Ultrasonic vibration-assisted machining reduces the average machining temperature through dynamic intermittent machining, and the micro-texture on the tool surface can improve friction reduction and clearance drainage heat dissipation at the tool-workpiece contact interface. However, a single processing method has limited improvement in high-efficiency and high-quality machining and will introduce unnecessary machining damage. Therefore, some hybrid processes have emerged. For example, a laser-ultrasonic synchronous assisted cutting system is disclosed in Patent CN202111460177.6; a hybrid machining method of ultrasonic laser machinery, an ultrasonic vibration fixture, a machine tool, a laser, etc. are disclosed in Patent CN202011232396.4. However, most of these energy field-assisted processes are not combined with tool strengthening technologies, and traditional cooling technologies cannot respond to the transient thermal field gradient changes in laser-ultrasonic energy field collaborative assisted machining, and cannot adapt to the asymmetric heat source distribution introduced by laser-assisted machining, greatly weakening the laser thermal-assisted softening effect and severely restricting high-efficiency machining. In addition, the laser preparation of the tool surface micro-texture and the laser-assisted machining process are usually implemented step by step, with a long process chain and increased equipment costs. Summary of the Invention

[0003] Aiming at the deficiencies in the prior art, the present invention provides a laser-ultrasonic collaborative texturing tool dynamic clearance heat dissipation hybrid machining device and method, which combines the laser-ultrasonic energy field-assisted process and the tool strengthening technology, uses the laser thermal softening effect to improve the machinability of difficult-to-machine materials, and at the same time, with the characteristics of ultrasonic vibration and micro-texture tool collaborative friction reduction and efficiency increase to improve the durability of the tool, breaking through the problem of high-quality and high-efficiency machining of difficult-to-machine materials.

[0004] To achieve the above object, the technical solution adopted by the present invention is as follows:

[0005] In the first aspect, the present invention provides a laser-ultrasonic collaborative texturing tool dynamic clearance heat dissipation hybrid machining method as follows:

[0006] Step 1) According to the material and shape characteristics of the parts to be machined, determine the configuration forms of the workpiece, the laser machining hybrid device, the ultrasonic vibration-assisted machining device, and the micro-texture tool, and design the surface micro-texture parameters of the tool;

[0007] Step 2) Clamp the tool on the ultrasonic vibration-assisted machining device, accurately position the tool at the micro-texture preparation station, and use the femtosecond laser of the laser machining composite device to prepare micro-textures on the tool surface.

[0008] Step 3) Clamp the workpiece, install the micro-texture tool on the ultrasonic vibration-assisted machining device, position the micro-texture tool at the composite machining station and complete tool setting. The laser machining composite device follows the ultrasonic vibration-assisted machining device. Adjust the laser machining composite device to preheat and soften the area to be machined with the auxiliary heat laser beam and suppress thermal damage. The ultrasonic vibration-assisted machining device makes the micro-texture tool perform ultrasonic vibration to achieve periodic intermittent machining, and carry out the machining feed process to complete the composite machining.

[0009] In a second aspect, the present invention also provides a laser-ultrasonic collaborative texture tool dynamic clearance heat dissipation composite machining device, including:

[0010] A driving spindle assembly, which is used to fix the workpiece and drive the workpiece to realize the movement of the workpiece in the Y-axis and the rotational movement around its own axis;

[0011] A micro-texture tool, which is installed on the ultrasonic vibration-assisted machining device and is used to machine the workpiece;

[0012] An ultrasonic vibration-assisted machining device, which is installed on a servo worktable with three-axis servo motion of the X-axis, Z-axis and rotary B-axis;

[0013] A laser machining composite device, which is installed on the servo worktable. The laser machining composite device includes a micro-texture machining laser source, an auxiliary heat laser source, a precision worktable, an optical path integration system, and a focusing and scanning system. The precision worktable is used for macroscopic position regulation of the laser beam. The optical path integration system dynamically switches the optical path to the micro-texture machining laser source or the auxiliary heat laser source according to the processing requirements. The focusing and scanning system is used to focus the laser beam on the micro-texture machining area on the tool surface or the area to be machined on the workpiece.

[0014] The laser-ultrasonic energy field collaborative micro-texture tool dynamic clearance heat dissipation composite machining of the present invention is realized through the spatio-temporal collaborative effect of multiple physical fields of the laser energy field, the ultrasonic vibration energy field and the micro-texture tool. Among them, the thermal effect of the laser energy field and the dynamic heat dissipation effect of the ultrasonic vibration energy field are synergistically used for thermal management to achieve local thermal softening of the material and suppress the temperature rise of the tool. While improving the machinability of the material, tool wear is suppressed. The ultrasonic vibration energy field and the micro-texture collaborative dynamic clearance strong time-varying heat dissipation are jointly realized by using the periodic time-varying effect of the gap between the ultrasonic vibration machining tool and the workpiece and the forced convection heat dissipation effect of the micro-texture channel as a directional heat dissipation channel. In the composite machining, the processing temperature, force, vibration and morphology during the processing are also fused and monitored.

[0015] As a further technical solution, the driving spindle assembly includes a Y-axis driving platform, a clamping device for fixing the workpiece, and a servo spindle for driving the workpiece. The clamping device is fixed to the output end of the servo spindle, and the servo spindle is fixed to the Y-axis driving platform. It can realize the functions of locking the spindle, slow servo motion, and conventional rotary motion, and can lock the workpiece, make the workpiece perform servo motion during the machining process, or make the workpiece perform conventional rotary motion;

[0016] As a further technical solution, the X-axis and Z-axis servo motions of the servo worktable can enable the laser processing composite device and the ultrasonic vibration assisted processing device to synchronously complete the machining feed motion, and the rotary B-axis can accurately position the tool at the micro-texture preparation station or the composite machining station.

[0017] As a further technical solution, the micro-texture processing laser source is a femtosecond pulsed laser source for preparing the micro-texture on the tool surface, and the auxiliary heating laser source is a nanosecond pulsed laser source or a continuous laser source for laser-assisted heating and softening the workpiece during the composite machining process.

[0018] As a further technical solution, the ultrasonic vibration assisted processing device can apply one-dimensional high-frequency vibration, two-dimensional high-frequency vibration, and three-dimensional high-frequency vibration to the micro-texture tool.

[0019] As a further technical solution, infrared temperature sensors, dynamometers, vibration meters, acoustic emission sensors, and high-speed cameras for monitoring the workpiece machining process and heat dissipation performance are also equipped around the driving spindle assembly and the servo worktable.

[0020] As a further technical solution, the ultrasonic vibration assisted processing device includes a transducer, a horn, and a tool clamping mechanism for applying high-frequency vibration to the micro-texture tool.

[0021] As a further technical solution, the micro-texture on the micro-texture tool includes heat dissipation guiding micro-texture and friction reducing micro-texture; the size of the heat dissipation guiding micro-texture is larger than that of the friction reducing micro-texture.

[0022] In the third aspect, based on the above laser-ultrasonic collaborative texturing tool dynamic gap heat dissipation composite machining device, the present invention provides a machining method for the laser-ultrasonic collaborative texturing tool dynamic gap heat dissipation composite machining device as follows:

[0023] Clamp the tool on the ultrasonic vibration assisted processing device, and use the laser beam emitted by the micro-texture processing laser source of the laser processing composite device to prepare the micro-texture on the tool surface to form a micro-texture tool;

[0024] The spindle assembly is driven to clamp the workpiece, so that the micro-texture tool is positioned at the composite processing station and the tool setting is completed. The servo worktable drives the laser processing composite device and the ultrasonic vibration auxiliary processing device to follow up. The laser processing composite device is adjusted so that the auxiliary heat laser beam preheats and softens the processing area and suppresses thermal damage. The ultrasonic vibration auxiliary processing device makes the micro-texture tool perform ultrasonic vibration to achieve periodic intermittent processing, and the processing tool path process is carried out to complete the composite processing.

[0025] As a further technical solution, during the processing of the workpiece, the processing parameters of the auxiliary heating laser beam are modulated, the laser type is selected as a nanosecond pulse laser beam, and the irradiation position is selected as a set distance in front of the micro-texture tool processing position to ensure that the area to be processed of the workpiece is locally heated and softened, and no thermal damage is caused to the micro-texture tool and the processed surface; the vibration frequency and amplitude of the ultrasonic vibration are set so that the ultrasonic vibration matches the parameters of the micro-texture tool and the auxiliary heating laser beam to achieve effective local thermal softening of the material. The high-frequency intermittent processing characteristics are used to decouple the laser thermal softening effect and the heat resistance of the micro-texture tool, and multi-scale collaborative heat dissipation of laser heat diffusion and processing heat is carried out.

[0026] The present invention achieves improved machinability of difficult-to-machine materials through deep fusion of laser-ultrasonic energy field and micro-texture tool, and ensures tool life and machining quality of parts through dynamic gap strong time-varying heat dissipation mechanism, which has the following beneficial effects:

[0027] 1) In the laser ultrasonic collaborative texturing tool dynamic gap heat dissipation composite processing device and method proposed in the present invention, the laser energy field

[0028] The multi-physical field space-time synergistic effect of ultrasonic vibration energy field and micro-texture tool realizes the composite processing of laser ultrasonic energy field and micro-texture tool dynamic gap heat dissipation; wherein the thermal effect of laser energy field and the dynamic heat dissipation effect of ultrasonic vibration energy field cooperate with thermal management to realize local thermal softening of material and suppress tool temperature rise, improve material machinability while suppressing tool wear, and the ultrasonic vibration energy field and micro-texture cooperate with dynamic gap strong time-varying heat dissipation to utilize the periodic time-varying effect of the gap between ultrasonic vibration machining tool and workpiece and cooperate with the forced convection heat dissipation effect of micro-texture groove as a directional heat dissipation channel to achieve it together.

[0029] 2) In the composite processing, the processing temperature and the force, vibration and shape of the processing process are also integrated and monitored; ultrasonic vibration induces intermittent contact between the tool and the workpiece, and the micro-texture groove provides a directional guide gap in the tool-workpiece contact area. The ultrasonic vibration cooperates with the tool micro-texture to improve the heat dissipation efficiency during the processing, significantly improving the adverse thermal damage to the workpiece and the tool introduced while laser-assisted machinability improvement of difficult-to-process materials, thereby improving the tool life and processing surface integrity.

[0030] 3) The laser processing of micro-textures and the laser-assisted heating function are integrated into the same device. Through dynamic switching of the optical path, time-sharing multiplexing is achieved, reducing equipment costs, eliminating redundant processes, and improving processing efficiency.

[0031] 4) Through the multi-physical-field spatio-temporal synergistic effect of the laser energy field, ultrasonic vibration energy field, and micro-textured tool, this method and device break through the problem of high-quality and high-efficiency processing of difficult-to-machine materials, and achieve the improvement and wide application of the service performance of high-end equipment components. BRIEF DESCRIPTION OF THE DRAWINGS

[0032] The following drawings are only intended to illustrate and explain the present invention, and do not limit the scope of the present invention.

[0033] Figure 1 It is a schematic diagram of an embodiment of the laser-ultrasonic collaborative texturing tool dynamic clearance heat dissipation composite processing method of the present invention.

[0034] Figure 2(a) is a schematic diagram of the cross-scale micro-groove textured tool disclosed by the present invention;

[0035] Figure 2(b) is a schematic diagram of the micro-groove and ellipse composite textured tool disclosed by the present invention;

[0036] Figure 2(c) is a schematic diagram of the diamond and ellipse composite textured tool disclosed by the present invention;

[0037] Figure 2(d) is a schematic diagram of the triangle, circle and ellipse composite textured tool disclosed by the present invention;

[0038] Figure 2(e) is a schematic diagram of the arc and micro-groove composite textured tool disclosed by the present invention;

[0039] Figure 3 It is a schematic diagram of an embodiment of the laser-ultrasonic collaborative texturing tool dynamic clearance heat dissipation composite processing device disclosed by the present invention;

[0040] Figure 4 It is a schematic diagram of the structure of an embodiment of the laser processing composite device of the laser-ultrasonic collaborative texturing tool dynamic clearance heat dissipation composite processing device disclosed by the present invention;

[0041] Figure 5 It is a schematic diagram of an embodiment of the optical path integration system in the laser processing composite device disclosed by the present invention;

[0042] Figure 6 It is a schematic diagram of an embodiment of the focusing and scanning system in the laser processing composite device disclosed by the present invention;

[0043] Figure 7 It is a schematic diagram of the preparation of the micro-textured tool disclosed by the present invention;

[0044] Figure 8It is a schematic diagram of the composite machining of the end face of a round bar workpiece disclosed by the present invention.

[0045] In the figure, 1. workpiece, 2. laser machining composite device, 3. ultrasonic vibration assisted machining device, 4. micro-textured tool, 5. driving spindle assembly, 6. acoustic emission sensor, 7. vibration meter, 8. fixed base, 9. high-speed camera, 10. infrared temperature sensor, 11. dynamometer, 12. servo workbench, 13. micro-texturing laser source, 14. optical path integration system, 15. focusing and scanning system, 16. auxiliary heating laser source, 17. precision workbench, 18. optical path switching mirror, 19. laser output optical path, 20. digital scanning galvanometer, 21. focusing lens;

[0046] a1. Laser heat diffusion, a2. Laser heat softening, a3. Ultrasonic vibration, a4. Heat convection, a5. Dynamic gap time-varying heat dissipation, a6. Micro-texture guided heat dissipation, a7. Heat generated during machining, a8. Time-varying intermittent heat dissipation, b1. Cross-scale micro-groove texture, b2. Micro-groove and ellipse composite texture, b3. Rhombus and ellipse composite texture, b4. Triangle, circle and ellipse composite texture, b5. Arc and micro-groove composite texture, s1. Femtosecond laser beam, s2. Auxiliary heating laser beam, v. Workpiece speed direction. Specific embodiments

[0047] The present invention will be further described below in conjunction with the drawings and embodiments. In the following detailed description, only the preferred embodiments of the present invention are described by way of illustration. Undoubtedly, those of ordinary skill in the art can recognize that the described embodiments can be modified in various different ways without departing from the spirit and scope of the present invention. Therefore, the drawings and the description are illustrative in nature and not used to limit the protection scope of the claims.

[0048] Glossary: In this embodiment, the top horizontal plane of the fixed base 8 is used as a reference to define the X-axis, Y-axis and Z-axis. Among them, the X-axis and Z-axis are perpendicular to each other on the horizontal plane, and the Y-axis is a vertical axis perpendicular to the horizontal plane; the rotary B-axis is perpendicular to the horizontal plane and parallel to the Y-axis.

[0049] Based on the problems existing in the prior art that the traditional cooling technology cannot respond to the transient thermal field gradient changes in the laser and ultrasonic energy field assisted machining, and cannot adapt to the asymmetric heat source distribution introduced by laser assisted machining, greatly weakening the laser thermal assisted softening effect and severely restricting high-efficiency machining; and the processes of laser preparing tool surface micro-textures and laser assisted machining are usually implemented step by step, with a long process chain and increased equipment costs, this embodiment provides a composite machining method combining multi-energy field assistance and tool micro-texture strengthening technology. Through the synergistic action of laser-ultrasonic energy fields and micro-texture strengthening of the tool, the machining performance of difficult-to-machine materials is improved, tool wear is inhibited, and the technical bottleneck of high-quality and high-efficiency machining of difficult-to-machine materials is broken through.

[0050] Embodiment 1

[0051] This embodiment provides a composite machining method for dynamic clearance heat dissipation of a laser-ultrasonic collaborative textured tool. The method disclosed in this embodiment will be described in detail below with reference to the accompanying drawings: Refer to Figure 1 , and the composite machining method for dynamic clearance heat dissipation of a laser-ultrasonic collaborative textured tool specifically includes the following steps:

[0052] 1) Determine the configuration form of energy field collaborative machining: The material of the parts to be machined is generally difficult-to-machine materials such as titanium alloy and superalloy, and the shape features are generally plane, rotary surface and cylindrical end face; determine the configuration form of workpiece 1, laser machining composite device 2, ultrasonic vibration assisted machining device 3, and micro-textured tool 4; design the shape and preparation position of the surface micro-texture of micro-textured tool 4. The preparation position is generally the rake face and flank face of the tool, and the shape can be cross-scale micro-groove texture b1, micro-groove and ellipse composite texture b2, diamond and ellipse composite texture b3, triangle, circle and ellipse composite texture b4, arc and micro-groove composite texture b5. Specifically, refer to Fig. 2(a), Fig. 2(b), Fig. 2(c), Fig. 2(d), Fig. 2(e);

[0053] 2) Prepare the micro-textured tool 4: Clamp the tool on the ultrasonic vibration assisted machining device 3, adjust the position to accurately position the tool at the micro-texture preparation station, and use a femtosecond laser beam s1 to prepare the micro-texture on the tool surface to complete the preparation of the micro-textured tool 4.

[0054] 3) Develop the compound machining process of laser-ultrasonic energy field synergistic micro-textured tool 4 dynamic clearance heat dissipation: Clamp the workpiece 1, install the micro-textured tool 4 on the ultrasonic vibration-assisted machining device 3, adjust the position of the ultrasonic vibration-assisted machining device 3 so that the micro-textured tool 4 is positioned at the compound machining station and complete the tool setting; during the machining process, the laser machining compound device 2 and the ultrasonic vibration-assisted machining device 3 move synchronously to ensure that the distance between the auxiliary heating laser beam s2 and the micro-textured tool 4 is maintained at 1 - 10 mm; adjust the laser machining compound device 2 to align the auxiliary heating laser beam s2 with the surface of the area to be machined, and perform local laser thermal softening a2 on the workpiece 1; at the same time, the ultrasonic vibration-assisted machining device 3 makes the micro-textured tool 4 perform ultrasonic vibration a3, and the micro-textured tool 4 makes periodic intermittent contact with the workpiece 1 to achieve periodic intermittent machining during the machining process; the workpiece moves along the workpiece velocity direction v to perform the machining feed process and complete the compound machining of the workpiece 1.

[0055] 4) Modulate the laser-ultrasonic energy field synergistic assisted machining parameters: Modulate the machining parameters of the auxiliary heating laser beam s2, select the laser type as a nanosecond pulsed laser beam, the laser power is 5 - 80 W, the pulse width is 100 ns, the spot diameter is about 1 μm, and the irradiation position is selected 6 mm in front of the machining position of the micro-textured tool 4. Do not use the laser beam scanning setting to ensure that the area to be machined of the workpiece 1 is locally heated and softened, and no thermal damage is caused to the micro-textured tool 4 and the machined surface; set the vibration frequency of the ultrasonic vibration a3 to 20 - 100 kHz, the amplitude to 5 - 20 μm, and the ultrasonic vibration a3 matches the parameters of the micro-textured tool 4 and the auxiliary heating laser beam s2. On the basis of realizing local effective thermal softening of the material, using the high-frequency intermittent machining characteristics, decouple the laser thermal softening a2 effect and the heat resistance of the micro-textured tool 4, and perform multi-scale synergistic heat dissipation on the laser thermal diffusion a1 and the machining heat generation a7.

[0056] Based on the above steps, the laser machining compound device 2, the ultrasonic vibration-assisted machining device 3 and the micro-textured tool 4 work together to exert the synergistic effects of the laser thermal softening a2 effect, the ultrasonic time-varying intermittent heat dissipation a8 and the micro-textured drainage heat dissipation a6, realizing the high-efficiency and high-quality machining of the workpiece 1 and extending the service life of the micro-textured tool 4; the thermal effect of the laser energy field and the dynamic heat dissipation effect of the ultrasonic vibration a3 energy field synergistically manage heat to achieve local thermal softening of the workpiece 1 and suppress the tool temperature rise, improving the machinability of the material while suppressing tool wear. The ultrasonic vibration a3 energy field and the micro-textured synergistic dynamic clearance strong time-varying heat dissipation a5 utilize the gap periodic time-varying effect between the tool and the workpiece 1 during ultrasonic vibration a3 machining and the forced convection heat dissipation effect of the micro-textured groove as a directional heat dissipation channel to jointly achieve, breaking through the limitation of only dissipating heat through thermal convection a4 in traditional machining; during the compound machining process, monitor the machining temperature, force, vibration, and morphology of the machining process to further optimize the machining process.

[0057] Example 2

[0058] The laser-ultrasonic collaborative texturing tool dynamic clearance heat dissipation composite machining device provided in this embodiment will be described in detail below in conjunction with the accompanying drawings:

[0059] Specifically, referring to Figure 3 , Figure 4 , Figure 5 , Figure 6 , Figure 7 , Figure 8 , this embodiment provides a laser-ultrasonic collaborative texturing tool dynamic clearance heat dissipation composite machining device, including a driving spindle assembly 5, a fixed base 8, a servo workbench 12, a laser machining composite device 2, an ultrasonic vibration assisted machining device 3, and a micro-texturing tool 4;

[0060] The laser machining composite device 2 only moves in the X and Z axes; the ultrasonic vibration assisted machining device 3 is installed on the B axis.

[0061] Among them, the driving spindle assembly 5 is used to fix the workpiece 1 and drive the workpiece 1 to realize the movement of the workpiece 1 in the Y axis (vertical direction) and the rotational movement around its own axis;

[0062] The micro-texturing tool 4 is installed on the ultrasonic vibration assisted machining device 3 and is used for cutting the workpiece 1;

[0063] The ultrasonic vibration assisted machining device 3 is installed on a servo workbench 12 with three-axis servo motion of the X axis, Z axis, and rotary B axis;

[0064] The laser machining composite device 2 is installed on the servo workbench 12 with three-axis servo motion of the X axis, Z axis, and rotary B axis. Among them, the laser machining composite device 2 moves in the X and Z axis directions, and the ultrasonic vibration assisted machining device 3 can move in the X and Z axis directions and can also rotate in the B axis direction;

[0065] The laser machining composite device 2 includes a micro-texturing processing laser source 13, an auxiliary heat laser source 16, a precision workbench 17, an optical path integration system 14, and a focusing and scanning system 15. Among them, the precision workbench 17 is used for macroscopic position regulation of the laser beam, and the optical path integration system 14 can dynamically switch the optical path to the micro-texturing processing laser source 13 or the auxiliary heat laser source 16 according to the processing requirements, and the focusing and scanning system 15 is used to focus the laser beam on the micro-texturing processing area on the tool surface or the area to be processed of the workpiece 1;

[0066] The driving spindle assembly 5 and the servo workbench 12 are installed on the fixed base 8, and the servo workbench 12 drives the ultrasonic vibration assisted machining device 3 and the laser machining composite device 2 to feed synchronously, and can simultaneously perform laser auxiliary heating and ultrasonic vibration a3 assisted machining on the workpiece 1.

[0067] The composite machining of the laser ultrasonic energy field synergistic micro-textured tool with dynamic clearance heat dissipation in the present invention is realized through the spatio-temporal synergistic effect of the multi-physical fields of the laser energy field, the ultrasonic vibration a3 energy field, and the micro-textured tool 4. Among them, the thermal effect of the laser energy field and the dynamic heat dissipation effect of the ultrasonic vibration a3 energy field are synergistically thermally managed to achieve local thermal softening of the material and suppress the tool temperature rise, while improving the machinability of the material and suppressing tool wear. The ultrasonic vibration a3 energy field and the micro-texture synergistic dynamic clearance strong time-varying heat dissipation a5 are jointly realized by using the periodic time-varying effect of the gap between the ultrasonic vibration a3 machining tool and the workpiece 1 and the forced convection heat dissipation effect of the micro-texture channel as a directional heat dissipation channel; in the composite machining, the machining temperature, force, vibration, and morphology during the machining process are also fused and monitored.

[0068] Furthermore, the above-mentioned driving spindle assembly 5 can realize the translational motion of the servo spindle along the Y-axis. The servo spindle can realize locking the spindle, slow servo motion, and conventional rotary motion, and can lock the workpiece 1, make the workpiece 1 perform servo motion along with the machining process, or make the workpiece 1 perform conventional rotary motion.

[0069] Furthermore, the servo workbench 12 can provide three-axis servo motions of the X-axis, Z-axis, and rotary B-axis. Among them, the X-axis and Z-axis servo motions can enable the laser machining composite device 2 and the ultrasonic vibration-assisted machining device 3 to move synchronously to complete the machining feed, and the rotary B-axis can accurately position the tool at the micro-texture preparation station or the composite machining station.

[0070] Furthermore, the above-mentioned laser machining composite device 2 includes a micro-texture machining laser source 13, an auxiliary heat laser source 16, a precision workbench 17, an optical path integration system 14, a focusing and scanning system 15, etc. Among them, the micro-texture machining laser source 13 is a femtosecond pulsed laser source, and the auxiliary heat laser source 16 is a nanosecond pulsed laser source or a continuous laser source; the precision workbench 17 adjusts the macroscopic position of the laser beam by regulating the positions and angles of the optical path integration system 14 and the focusing and scanning system 15; when preparing the micro-texture tool 4, the optical path integration system 14 switches the optical path to the micro-texture machining laser source 13 through the optical path switching mirror 18, reflects the laser beam emitted by the micro-texture machining laser source 13 to the laser output optical path 19, and when performing composite machining, switches the optical path to the auxiliary heat laser source 16 through the optical path switching mirror 18, and reflects the laser beam emitted by the auxiliary heat laser source 16 to the laser output optical path 19; the focusing and scanning system 15 regulates the position of the output laser beam through the digital scanning galvanometer 20, and the focusing lens 21 is used to adjust the spot size of the laser beam.

[0071] Furthermore, the ultrasonic vibration-assisted machining device 3 can apply one-dimensional, two-dimensional, or three-dimensional high-frequency vibrations to the micro-texture tool 4.

[0072] Further, acoustic emission sensors 6, vibration meters 7, high-speed cameras 9, and infrared temperature sensors 10 for monitoring the machining process and heat dissipation performance of the workpiece 1 are also provided around the driving spindle assembly 5 and the servo workbench 12. A dynamometer 11 is installed between the ultrasonic vibration-assisted machining device 3 and the servo workbench 12.

[0073] Further, the surface micro-texture parameters of the micro-textured tool 4 are designed according to the machining requirements of the parts and the performance requirements of friction reduction, heat dissipation, and chip evacuation during machining. The surface micro-texture parameters are the shape and preparation position of the surface micro-texture. The shape includes but is not limited to micro-grooves, micro-pits, polygons, ellipses, arcs, and honeycombs. The surface micro-texture is a different cross-scale combination form of the above shapes. The heat dissipation and guiding micro-texture is a large-scale groove. The preparation position of the surface micro-texture is the rake face or the flank face of the tool. For the surface micro-texture of the micro-textured tool 4, reference can be made to Fig. 2(a), Fig. 2(b), Fig. 2(c), Fig. 2(d), and Fig. 2(e). Fig. 2(a) shows the cross-scale micro-groove texture b1; Fig. 2(b) shows the composite texture b2 of micro-grooves and an ellipse; Fig. 2(c) shows the composite texture b3 of a rhombus and an ellipse; Fig. 2(d) shows the composite texture b4 of a triangle, a circle, and an ellipse; Fig. 2(e) shows the composite texture b5 of an arc and micro-grooves.

[0074] Further, among the laser-ultrasonic energy field collaborative-assisted machining parameters, the laser-assisted heat processing parameters can decouple the local thermal softening zone from the heat resistance of the micro-textured tool 4, and the ultrasonic vibration can cooperate with the micro-textured tool 4 to achieve multi-scale collaborative heat dissipation.

[0075] Further, the above-mentioned laser-ultrasonic collaborative texturing tool dynamic clearance heat dissipation composite machining device is specifically implemented as follows:

[0076] 1) According to the shape characteristics of the end face of the round bar of the workpiece 1, determine the machining configuration form as: the workpiece 1 is clamped on the driving spindle assembly 5, the laser machining composite device 2 and the ultrasonic vibration-assisted machining device 3 are assembled on the servo workbench 12. Among them, the ultrasonic vibration-assisted machining device 3 is installed on the rotary B-axis of the servo workbench 12, the micro-textured tool 4 is installed on the ultrasonic vibration-assisted machining device 3, design the surface micro-texture parameters of the tool as the cross-scale micro-groove texture b1, and the preparation position is the rake face of the tool.

[0077] 2) Install the micro-textured tool 4 on the ultrasonic vibration-assisted machining device 3, and drive the rotary B-axis of the servo workbench 12 to accurately position the tool at the micro-texture preparation station (see Figure 7(at the position of the micro-textured tool 4), adjust the laser processing composite device 2 to position the laser beam on the rake face of the tool, switch the optical path to make the femtosecond pulsed laser source work, set the laser power to 50 W, the pulse width to 200 fs, and use the femtosecond pulsed laser beam to prepare cross-scale micro-groove textures b1 on the rake face of the tool. During the preparation process, use a high-speed camera 9 to monitor the preparation process of the micro-textured tool 4, and use an infrared temperature sensor 10 to observe the temperature field distribution of the laser processing micro-textures.

[0078] 3) Formulate the compound processing process as follows: Clamp the workpiece 1 on the driving spindle assembly 5, install the micro-textured tool 4 on the ultrasonic vibration-assisted processing device 3, adjust the servo workbench 12 to position the micro-textured tool 4 at the compound processing station and complete the tool setting (see Figure 8 (at the position of the micro-textured tool 4). Install the laser processing composite device 2 and the ultrasonic vibration-assisted processing device 3 on the servo workbench 12 to achieve synchronous feed movement; adjust the laser processing composite device 2 to align the auxiliary heating laser beam with the area to be processed on the workpiece 1 for local laser thermal softening a2, and the distance between the auxiliary heating laser beam and the micro-textured tool 4 is 1 - 10 mm; at the same time, the ultrasonic vibration-assisted processing device 3 makes the micro-textured tool 4 perform ultrasonic vibration a3 to achieve periodic intermittent processing; lock the driving spindle assembly 5 and drive the servo workbench 12 to perform machining feed.

[0079] 4) Modulate the processing parameters of the nanosecond pulsed laser beam of the laser processing composite device 2, set the laser power to 20 W, the pulse width to 100 ns, the spot diameter to 1 μm, and select the irradiation position 6 mm in front of the processing position of the micro-textured tool 4 to ensure local heating and softening of the area to be processed on the workpiece 1 without causing adverse thermal damage to the micro-textured tool 4 and the machined surface; set the processing parameters of the ultrasonic vibration-assisted processing device 3, the vibration frequency to 20 kHz, the amplitude to 10 μm, and the vibration dimension to one-dimensional longitudinal vibration, to match the parameters of the laser processing composite device 2 and the micro-textured tool 4 during the compound processing process, and on the basis of realizing effective thermal softening of the material, utilize the high-frequency intermittent processing characteristics to decouple the laser thermal softening a2 effect and the heat resistance of the micro-textured tool 4, and perform multi-scale collaborative forced gap heat dissipation on the laser thermal diffusion a1 and the machining heat generation a7.

[0080] 5) An acoustic emission sensor 6 is used to monitor the machining defects of the workpiece 1, a vibration measuring instrument 7 is used to monitor the ultrasonic vibration a3 state of the cutting tool, a high-speed camera 9 is used to monitor the material removal process during the hybrid machining process, an infrared temperature sensor 10 is used to monitor the heat dissipation performance during the hybrid machining process, a dynamometer 11 is used to monitor the force signal during the hybrid machining process, and multi-sensor fusion monitoring is used to provide feedback guidance for the hybrid machining process; the laser machining hybrid device 2, the ultrasonic vibration-assisted machining device 3, the micro-textured cutting tool 4, the driving spindle assembly 5 and the servo workbench 12 work together to perform hybrid machining, giving play to the synergistic effect of the laser thermal softening a2 effect, the ultrasonic time-varying intermittent heat dissipation a8 and the micro-textured heat dissipation a6, improving the machinability of the material and performing dynamic clearance strong time-varying heat dissipation a5 during the machining process, improving the machining quality and tool life, and realizing high-efficiency and high-quality machining of difficult-to-machine materials.

[0081] In the laser-ultrasonic collaborative textured tool dynamic clearance heat dissipation hybrid machining device and method proposed in this embodiment, through the laser energy field

[0082] and the ultrasonic vibration a3 energy field, and the multi-physical-field spatio-temporal collaborative effect of the micro-textured cutting tool 4, laser-ultrasonic energy field collaborative micro-textured cutting tool 4 dynamic clearance heat dissipation hybrid machining is realized; among them, the thermal effect of the laser energy field and the dynamic heat dissipation effect of the ultrasonic vibration a3 energy field are used for collaborative thermal management to achieve local thermal softening of the material and suppress the tool temperature rise, suppressing tool wear while improving the machinability of the material. The ultrasonic vibration a3 energy field and the micro-texture collaborative dynamic clearance strong time-varying heat dissipation a5 are jointly realized by using the gap periodic time-varying effect between the ultrasonic vibration a3 cutting tool and the workpiece 1 and the forced convection heat dissipation effect of the micro-texture groove as a directional heat dissipation channel.

[0083] The laser-ultrasonic collaborative textured tool dynamic clearance heat dissipation hybrid machining device and method proposed in this embodiment can be used for the manufacturing of components in high-end equipment such as aerospace and energy equipment. High-end equipment such as aerospace and energy equipment faces requirements such as extreme service environments, high reliability, and long life. The core components have an increasing demand for difficult-to-machine materials with excellent properties such as superalloys and titanium alloys. The material processing and removal process plays a core role in the manufacturing process of core components. The aggravation of tool wear and the deterioration of surface integrity during the machining process have become serious bottlenecks restricting the application of difficult-to-machine materials; the manufacturing process of core components of high-end equipment supported by high-quality and high-efficiency cutting technology has extremely high requirements for machining processes and cutting tools, etc. The laser-ultrasonic collaborative textured tool dynamic clearance heat dissipation hybrid machining device and method proposed in this invention can ensure the high integrity and excellent service performance of the machined surface of components, improve production efficiency, and break through the technical problems of high-quality and high-efficiency machining of difficult-to-machine materials that restrict the development of high-end manufacturing.

[0084] The above are only the preferred embodiments of the present invention, and are not intended to limit the present invention in any other form. Any person skilled in the relevant art may use the technical content disclosed above to make changes or modifications to equivalent embodiments with equivalent changes. However, any simple modifications, equivalent changes and modifications made to the above embodiments based on the technical essence of the present invention without departing from the technical content of the present invention still fall within the protection scope of the technical solution of the present invention.

Claims

1. A laser ultrasonic collaborative texturing tool dynamic gap heat dissipation composite processing method, characterized in that: as follows: Step 1) according to the material and shape characteristics of the parts to be processed, determine the configuration of the workpiece, the laser processing composite device, the ultrasonic vibration assisted processing device, and the micro-texture tool, and design the surface micro-texture parameters of the tool; Step 2) clamping the tool in an ultrasonic vibration assisted processing device, positioning the tool precisely at the micro-texture preparation station, and using a femtosecond laser of a laser processing composite device to prepare micro-texture on the tool surface; Step 3) clamping the workpiece, installing the micro-texture tool on the ultrasonic vibration assisted processing device, positioning the micro-texture tool at the composite processing station and completing the tool alignment, the laser processing composite device and the ultrasonic vibration assisted processing device follow, adjusting the laser processing composite device so that the auxiliary heating laser beam performs laser preheating and softening on the processing area and inhibits thermal damage, and the ultrasonic vibration assisted processing device causes the micro-texture tool to perform ultrasonic vibration to achieve periodic intermittent processing, and the processing tool passing process is performed to complete the composite processing.

2. A laser ultrasonic collaborative texturing tool dynamic gap heat dissipation composite processing device, characterized in that: include: A driving spindle assembly is used to fix the workpiece and drive the workpiece to realize the movement of the workpiece on the Y axis and the rotational movement around its own axis; A micro-textured tool mounted on an ultrasonic vibration-assisted machining device for cutting a workpiece; An ultrasonic vibration-assisted machining device mounted on a servo table having three-axis servo motion of an X-axis, a Z-axis and a rotary B-axis; A laser processing composite device is installed on the servo workbench, and the laser processing composite device includes a micro-texturing processing laser source, an auxiliary heating laser source, a precision workbench, an optical path integration system, and a focusing scanning system, wherein the precision workbench is used for macro-position control of the laser beam, the optical path integration system dynamically switches the optical path to the micro-texturing processing laser source or the auxiliary heating laser source according to processing requirements, and the focusing scanning system is used to focus the laser beam on the micro-texturing processing area of ​​the tool surface or the area to be processed of the workpiece.

3. The laser ultrasonic collaborative texturing tool dynamic gap heat dissipation composite processing device according to claim 2, characterized in that: The driving spindle assembly comprises a Y-axis driving platform, a clamping device for fixing a workpiece and a servo spindle for driving the workpiece, wherein the clamping device is fixed to the output end of the servo spindle, and the servo spindle is fixed to the Y-axis driving platform.

4. The laser ultrasonic collaborative texturing tool dynamic gap heat dissipation composite processing device according to claim 2, characterized in that: The X-axis and Z-axis servo motions of the servo workbench can enable the laser processing composite device and the ultrasonic vibration auxiliary processing device to synchronously complete the processing feed motion, and the rotating B axis can accurately position the tool at the micro-texture preparation station or the composite processing station.

5. The laser ultrasonic collaborative texturing tool dynamic gap heat dissipation composite processing device according to claim 2, characterized in that: The micro-texturing laser source is a femtosecond pulse laser source, which is used to prepare micro-texture on the tool surface. The auxiliary heat laser source is a nanosecond pulse laser source or a continuous laser source, which is used for laser auxiliary heat softening of the workpiece during the composite processing process.

6. The laser ultrasonic collaborative texturing tool dynamic gap heat dissipation composite processing device according to claim 2, characterized in that: The ultrasonic vibration assisted processing device can apply one-dimensional high-frequency vibration, two-dimensional high-frequency vibration and three-dimensional high-frequency vibration to the micro-textured tool.

7. The laser ultrasonic collaborative texturing tool dynamic gap heat dissipation composite processing device according to claim 2, characterized in that: The driving spindle assembly and the servo workbench are also equipped with infrared temperature sensors, dynamometers, vibrometers, acoustic emission sensors and high-speed cameras for monitoring the workpiece processing process and heat dissipation performance.

8. The laser ultrasonic collaborative texturing tool dynamic gap heat dissipation composite processing device according to claim 2, characterized in that: The ultrasonic vibration assisted processing device comprises a transducer, an amplitude change rod and a tool clamping mechanism, and is used for applying high-frequency vibration to the micro-texturing tool.

9. The laser ultrasonic collaborative texturing tool dynamic gap heat dissipation composite processing device according to claim 2, characterized in that: The micro-texture on the micro-texture tool includes a heat dissipation guiding micro-texture and a friction reducing micro-texture; the size of the heat dissipation guiding micro-texture is larger than that of the friction reducing micro-texture.

10. The processing method of the laser ultrasonic collaborative texturing tool dynamic gap heat dissipation composite processing device according to any one of claims 2 to 9, characterized in that: The tool is clamped on the ultrasonic vibration assisted processing device, and a micro-texture is prepared on the surface of the tool by using a laser beam emitted by a micro-texture processing laser source of a laser processing composite device to form a micro-texture tool; The spindle assembly is driven to clamp the workpiece, so that the micro-texture tool is positioned at the composite processing station and the tool setting is completed. The servo worktable drives the laser processing composite device and the ultrasonic vibration auxiliary processing device to follow up. The laser processing composite device is adjusted so that the auxiliary heat laser beam preheats and softens the processing area and suppresses thermal damage. The ultrasonic vibration auxiliary processing device makes the micro-texture tool perform ultrasonic vibration to achieve periodic intermittent processing, and the processing tool path process is carried out to complete the composite processing.

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