Ultrasonic auxiliary welding device and method for micro cutter

Abstract

The invention discloses an ultrasonic auxiliary welding device and method for a micro cutter, and particularly relates to the technical field of micro cutter welding machining. The ultrasonic auxiliary welding device comprises a mounting frame, an ultrasonic vibration mechanism, a welding clamp and a pressure applying mechanism; the mounting frame comprises a base and a vertical plate vertically and fixedly connected with the base; the ultrasonic vibration mechanism is fixedly mounted on the base, is connected with the welding fixture and is used for applying overclocking vibration to the welding fixture; the welding fixture is used for placing the cutter handle and the cutter head; the pressure applying mechanism is installed on the vertical plate and used for applying pressure to the cutter handle on the welding clamp. Stable welding pressure can be provided, the bonding strength of the tool bit and the tool handle is enhanced, and the machining efficiency and the machining quality are improved.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of micro tool welding processing, in particular to a micro tool ultrasonic auxiliary welding device and method. BACKGROUND

[0002] With the rapid development of high-end manufacturing fields such as aerospace and precision instruments, the market demand for micro precision parts is growing explosively, and the quality of superhard micro tools (such as PCD polycrystalline diamond, CBN cubic boron nitride, single crystal diamond, etc.) directly determines the precision and stability of high-precision micro part manufacturing, and becomes one of the key links restricting the upgrading of high-end manufacturing.

[0003] In the production and manufacturing of superhard micro tools, due to the high cost of superhard raw materials, the extremely high processing difficulty and the small diameter of the tool edge, the industry generally adopts a welded tool structure, that is, the tool tip of the tool core adopts PCD material with excellent performance to ensure cutting precision and service life; and the tool handle part selects hard alloy or other alternative materials with lower cost and easier processing, which controls the cost while meeting the overall structural strength requirement of the tool. This design scheme makes the welding process of PCD tool tip and hard alloy tool handle the core link in the production process of superhard micro tools.

[0004] However, the current mainstream welding process has significant shortcomings: most process schemes have not systematically studied and optimized the influence of welding conditions on the final welding quality, resulting in two key problems frequently occurring in the production process. Either the solder is excessively extruded due to excessive welding pressure, damaging the integrity of the welding interface; or the gap between the tool handle and the tool tip is too large due to insufficient welding pressure, resulting in insufficient bonding strength. These problems directly lead to low production yield of superhard micro tools, not only increasing the manufacturing cost, but also seriously restricting the production efficiency of the welding process, which is difficult to meet the large-scale and high-quality demand for superhard micro tools in high-end manufacturing fields. SUMMARY

[0005] The purpose of the present application is to provide a micro tool ultrasonic auxiliary welding device and method to solve the problems existing in the prior art, which can provide stable welding pressure, enhance the bonding strength of the tool head and the tool handle, and improve the processing efficiency and processing quality.

[0006] To achieve the above purpose, the present application provides the following scheme: The application provides a micro tool ultrasonic auxiliary welding device, which comprises a mounting frame, an ultrasonic vibration mechanism, a welding clamp and a pressing mechanism; the mounting frame comprises a base and a vertical plate fixedly connected with the base; the ultrasonic vibration mechanism is fixedly installed on the base and connected with the welding clamp, and is used for applying ultrasonic vibration to the welding clamp; the welding clamp is used for placing a tool shank and a tool head; the pressing mechanism is installed on the vertical plate and used for applying pressure to the tool shank on the welding clamp.

[0007] Preferably, the ultrasonic vibration mechanism comprises a shell, an ultrasonic power supply, a transducer and an ultrasonic amplitude transformer; the transducer is installed in the shell, the shell is fixedly connected with the base, the ultrasonic power supply is electrically connected with the transducer, the transducer is installed in the shell, one end of the ultrasonic amplitude transformer is connected with the transducer, and the other end of the ultrasonic amplitude transformer is fixedly connected with the welding clamp.

[0008] Preferably, the transducer comprises a back cover plate, a piezoelectric ceramic sheet and a copper electrode; the piezoelectric ceramic sheet and the copper electrode are sequentially stacked between the back cover plate and the ultrasonic amplitude transformer; the back cover plate, the piezoelectric ceramic sheet, the copper electrode and the ultrasonic amplitude transformer are threadedly connected by bolts; and the piezoelectric ceramic is electrically connected with the ultrasonic power supply through the copper electrode.

[0009] Preferably, the number of the ultrasonic vibration mechanisms is two, and the two ultrasonic vibration mechanisms are uniformly distributed at the bottom of the welding clamp.

[0010] Preferably, the welding clamp has an I-shaped cross section, and comprises a top plate, a bottom plate and a connecting plate; the top plate is connected with the bottom plate through the connecting plate; the top plate and the bottom plate are parallel to each other and have the same size; a plurality of through holes for placing tool shanks are formed in the top plate; and a plurality of blind holes for placing tool heads corresponding to the through holes are formed in the bottom plate.

[0011] Preferably, the fitting clearance between the through holes and the tool shanks is 0.01-0.03 mm, and the fitting clearance between the blind holes and the tool heads is 0.01-0.03 mm.

[0012] Preferably, the mounting frame further comprises a horizontal plate, the horizontal plate is fixedly connected with one end of the vertical plate away from the base, the vertical plate is provided with vertical sliding rails, the pressing mechanism comprises a driving device, a sliding block and a pressing plate, the driving device is fixedly installed on the horizontal plate, the output end of the driving device is fixedly connected with the pressing plate, the pressing plate is fixedly connected with the sliding block, the sliding block is connected with the sliding rails, and the driving device drives the pressing plate to move up and down to apply pressure to the tool shank.

[0013] Preferably, the driving device is a cylinder.

[0014] Preferably, the end face of the shank welded with the head is provided with a first groove, and the end face of the head welded with the shank is provided with a second groove.

[0015] The application also provides a method for using the micro tool ultrasonic auxiliary welding device, comprising the following steps: Step one, place the shank and the head on the welding clamp, and fill the flux between the head and the shank; Step two, use the pressing mechanism to apply pressure to the shank, and at the same time, weld the shank and the head by the welding device, so that the flux is converted into a molten state, and at the same time, start the ultrasonic vibration mechanism to generate high-frequency vibration to the welding clamp, which drives the shank and the head to vibrate, so that the flux is uniformly distributed in the gap between the head and the shank, until the head and the shank are welded.

[0016] The application has the following technical effects compared with the prior art: The application provides a micro tool ultrasonic auxiliary welding device and method, the welding clamp can ensure that the head and the shank maintain accurate relative positions before welding, avoiding misalignment caused by deviation during welding; the pressing mechanism can apply stable pressure to the shank on the welding clamp in the vertical direction; the ultrasonic vibration mechanism drives the head and the shank to vibrate at high frequency through the welding clamp, which can generate acoustic streaming effect in the molten flux, and the flux forms directional flow due to high-frequency vibration, which can quickly fill the small gap between the head and the shank, avoiding defects such as cavitation and incomplete penetration caused by insufficient flow of the flux in traditional welding, enhancing the bonding strength of the head and the shank, and improving the processing efficiency and processing quality. BRIEF DESCRIPTION OF DRAWINGS

[0017] In order to more clearly illustrate the technical solutions in the embodiments of the application or the prior art, the following will briefly introduce the drawings needed in the embodiments. Obviously, the drawings described below are only some embodiments of the application, and other drawings can be obtained by those skilled in the art without creative effort.

[0018] Figure 1 It is a structural schematic diagram of the micro tool ultrasonic auxiliary welding device. Figure 2 It is an exploded view of the micro tool ultrasonic auxiliary welding device. Figure 3 It is a structural schematic diagram of the ultrasonic vibration mechanism. Figure 4 It is a structural schematic diagram of the welding clamp. Figure 5It is a structural schematic view of the tool holder. Figure 6 It is a structural schematic view of the tool head.

[0019] In the figure: 1-base; 2-vertical plate; 3-horizontal plate; 4-pressing mechanism; 5-driving device; 6-sliding block; 7-pressing plate; 8-sliding rail; 9-welding clamp; 10-top plate; 11-bottom plate; 12-connecting plate; 13-through hole; 14-blind hole; 15-ultrasonic vibration mechanism; 16-housing; 17-ultrasonic amplitude bar; 18-back cover plate; 19-piezoelectric ceramic sheet; 20-copper electrode; 21-bolt; 22-flange; 23-tool holder; 24-tool head; 25-first groove; 26-second groove. DETAILED DESCRIPTION

[0020] The technical solutions in the embodiments of the present application will be described clearly and completely below with reference to the drawings in the embodiments of the present application. Obviously, the described embodiments are only part of the embodiments of the present application, rather than all the embodiments. Based on the embodiments in the present application, all other embodiments obtained by those skilled in the art without creative work fall within the scope of protection of the present application.

[0021] The purpose of the present application is to provide a micro tool ultrasonic auxiliary welding device and method to solve the problems existing in the prior art, which can provide stable welding pressure, enhance the bonding strength of the tool head and the tool holder, and improve the processing efficiency and processing quality.

[0022] In order to make the above-mentioned purposes, features and advantages of the present application more obvious and easy to understand, the present application will be further described in detail below with reference to the drawings and specific embodiments.

[0023] Embodiment 1 The present embodiment provides a micro tool ultrasonic auxiliary welding device, as shown in Figures 1-2As shown, the device includes a mounting frame, an ultrasonic vibration mechanism 15, a welding clamp 9 and a pressing mechanism 4; the mounting frame includes a base 1 and a vertical plate 2 fixedly connected with the base 1 perpendicularly; the ultrasonic vibration mechanism 15 is fixedly installed on the base 1, and is connected with the welding clamp 9, for applying ultrasonic vibration to the welding clamp 9; the welding clamp 9 is used for placing a shank 23 and a head 24; the pressing mechanism 4 is installed on the vertical plate 2, and is used for applying pressure to the shank 23 on the welding clamp 9. The welding clamp 9 can ensure that the head 24 and the shank 23 keep accurate relative positions before welding, so as to avoid misalignment caused by deviation during welding. The pressing mechanism 4 can apply stable pressure to the shank 23 on the welding clamp 9 in the vertical direction, so as to ensure that the shank 23 and the head 24 are in close contact during welding. The ultrasonic vibration mechanism 15 drives the head 24 and the shank 23 to vibrate at high frequency through the welding clamp 9. Such vibration can generate acoustic streaming effect in the molten flux, the flux forms directional flow due to high-frequency vibration, which can quickly fill the tiny gap between the head 24 and the shank 23, avoid defects such as voids and incomplete penetration caused by insufficient flowability of the flux in traditional welding, and in the molten state of the solder, the stable pressure can help to discharge the gas and residual impurities in the tiny gap between the head 24 and the shank 23, further promote the uniform distribution of the solder and the close contact of the interface, and finally form a high-strength welded joint without defects. The micro tool ultrasonic auxiliary welding device of the embodiment is suitable for high-frequency welding and vacuum welding, can simultaneously weld multiple types and specifications of micro tools, improve the processing efficiency of micro tool welding, improve the micro tool welding quality, and reduce the rate of defective products.

[0024] Further preferably in the embodiment of the present embodiment is that, as shown in Figure 3 The ultrasonic vibration mechanism 15 includes a housing 16, an ultrasonic power supply, a transducer and an ultrasonic amplitude transformer 17. The transducer is installed in the housing 16, the housing 16 is fixedly connected with the base 1, the ultrasonic power supply is electrically connected with the transducer, the transducer is installed in the housing 16, one end of the ultrasonic amplitude transformer 17 is connected with the transducer, and the other end of the ultrasonic amplitude transformer 17 is fixedly connected with the welding clamp 9.

[0025] Further preferably in the embodiment of the present embodiment, the transducer comprises a back cover plate 18, a piezoelectric ceramic sheet 19 and a copper electrode 20, the piezoelectric ceramic sheet 19 and the copper electrode 20 are sequentially stacked between the back cover plate 18 and the ultrasonic horn 17, the back cover plate 18, the piezoelectric ceramic sheet 19, the copper electrode 20 and the ultrasonic horn 17 are threadedly connected by a bolt 21, and the piezoelectric ceramic is electrically connected to the ultrasonic power supply through the copper electrode 20. The structural size of the transducer meets the multiple wavelength design requirement; the front section of the ultrasonic horn 17 is a circular truncated cone, the rear section is a cylinder, the large end surface of the circular truncated cone is connected to the cylinder, a flange 22 fixedly connected to the shell 16 is arranged at the connection position of the circular truncated cone and the cylinder, and the front end and the rear end of the ultrasonic horn 17 are both provided with threaded holes, the front end threaded hole is used for fixedly connecting with the welding fixture 9, and the rear end threaded hole is used for threadedly connecting with the bolt 21. During welding, the ultrasonic power supply excites high-frequency vibration of the transducer, which is amplified by the ultrasonic horn 17 and transmitted to the welding fixture 9, and at the same time, the ultrasonic auxiliary welding is performed by pressing the tool shank 23 through the air cylinder.

[0026] Further preferably in the embodiment of the present embodiment, the number of the ultrasonic vibration mechanisms 15 is two, and the two ultrasonic vibration mechanisms 15 are uniformly distributed at the bottom of the welding fixture 9.

[0027] Further preferably in the embodiment of the present embodiment, as shown in Figure 4 the cross section of the welding fixture 9 is an I-shaped section, the welding fixture 9 comprises a top plate 10, a bottom plate 11 and a connecting plate 12, the top plate 10 is connected to the bottom plate 11 through the connecting plate 12, the top plate 10 and the bottom plate 11 are parallel to each other and have the same size, a plurality of through holes 13 for placing the tool shanks 23 are arranged on the top plate 10, and a plurality of blind holes 14 for placing the tool heads 24 are arranged on the bottom plate 11 in one-to-one correspondence with the through holes 13. The plurality of through holes 13 are arranged along the two sides of the top plate 10, so that multiple tool welding can be simultaneously performed; the blind hole 14 is a tapered hole or a through hole 13 type composite hole, and can place tool heads 24 of different shapes.

[0028] Further preferably in the embodiment of the present embodiment, the fitting clearance between the through hole 13 and the tool shank 23 is 0.01-0.03 mm, and the fitting clearance between the blind hole 14 and the tool head 24 is 0.01-0.03 mm, which can ensure the coaxiality and perpendicularity of the through hole 13, the tool shank 23, the blind hole 14 and the tool head 24 during welding.

[0029] Further preferably in the implementation of the embodiment, the mounting frame further comprises a horizontal plate 3, which is fixedly connected perpendicularly to one end of the vertical plate 2 away from the base 1, and the vertical plate 2 is provided with vertical sliding rails 8, the pressing mechanism 4 comprises a driving device 5, a sliding block 6 and a pressing plate 7, the driving device 5 is fixedly installed on the horizontal plate 3, the output end of the driving device 5 is fixedly connected with the pressing plate 7, the pressing plate 7 is fixedly connected with the sliding block 6, the sliding block 6 is connected with the sliding rails 8, and the driving device 5 drives the pressing plate 7 to move up and down to exert pressure on the tool shank 23, and the driving device 5 is a pneumatic cylinder. The pressing mechanism 4 exerts controllable pressure on the tool shank 23 on the welding fixture 9 through the pressing plate 7, so as to ensure that the tool shank 23 and the tool head 24 are in close contact during welding. Compared with the pressing mechanism 4 in the conventional welding process in which the pressure is uncontrollable, the pressure of the pneumatic cylinder of the present application can be adjusted, so as to avoid the problems of extrusion of the solder due to excessive pressure or loose contact due to insufficient pressure, thereby causing virtual welding. The pneumatic cylinder can complete linear reciprocating motion, the lower end of the pneumatic cylinder piston rod is provided with a threaded hole, a bolt 21 can be used to connect the pressing plate 7, and the bottom surface of the pressing plate 7 is provided with a boss, the position of the boss is consistent with the through hole 13 on the welding fixture 9, so as to ensure the stability of the pressure exertion.

[0030] Further preferably in the implementation of the embodiment, as shown in Figures 5-6 the first groove 25 is formed in the end face of the tool shank 23, and the second groove 26 is formed in the end face of the tool head 24. The tool shank 23 and the tool head 24 can be welded by plug welding, flat welding or angle welding. The tool head 24 is made of PCD, CBN or other superhard materials, and can be in the form of a hard alloy substrate or without a substrate. The tool shank 23 is a hard alloy cylinder. Further preferably, the first groove 25 and the second groove 26 can be circular grooves, square grooves or semicircular grooves, which can enhance the bonding strength of the tool head 24, the tool shank 23 and the flux, effectively solve the problems of low efficiency and poor quality in the welding process of micro tools, and have good economic benefits.

[0031] Embodiment 2 The present embodiment provides a method for ultrasonic auxiliary welding of the micro tool of embodiment 1, which comprises the following steps: Step one, placing the tool shank 23 and the tool head 24 on the welding fixture 9 and filling the flux between the tool head 24 and the tool shank 23; Step two, exerting a certain pressure on the tool shank 23 by using the pressing mechanism 4, and welding the tool shank 23 and the tool head 24 by using a welding device, so that the flux is converted into a molten state, and at the same time, starting the ultrasonic vibration mechanism 15 to generate high-frequency vibration on the welding fixture 9, so that the welding fixture 9 drives the tool shank 23 and the tool head 24 to vibrate, so that the flux is uniformly distributed in the gap between the tool head 24 and the tool shank 23, until the tool head 24 and the tool shank 23 are welded.

[0032] By filling the flux between the micro cutter head 24 and the micro cutter handle 23, a certain pressure is applied to the to-be-welded cutter by using the air cylinder pressure mechanism 4, the to-be-welded cutter can be welded in the form of high-frequency welding, vacuum welding and the like, the flux is converted into a molten state, the ultrasonic vibration mechanism 15 drives the micro cutter head 24 and the micro cutter handle 23 to vibrate through high-frequency vibration, the flux is uniformly distributed in the gap between the micro cutter head 24 and the micro cutter handle 23, and finally the welding of the micro cutter is completed, the welding strength is ensured, and the phenomena of welding separation, virtual welding and the like during use are prevented.

[0033] The principles and implementation manners of the present application are described by using specific examples in the present application, and the above examples are only used to help understand the method of the present application and its core idea; meanwhile, for the general skilled in the art, the specific implementation manners and application ranges will be changed according to the idea of the present application. In conclusion, the content of the present specification should not be understood as the limitation of the present application.

Claims

1. A micro-tool ultrasonic-assisted welding apparatus, characterized by: The utility model provides a welding device for tool handle and tool head, including mounting frame, ultrasonic vibration mechanism, welding clamp and pressure mechanism, the mounting frame includes base and vertical plate fixedly connected with base, ultrasonic vibration mechanism is fixedly installed on base, ultrasonic vibration mechanism is connected with welding clamp, is used for exerting ultrasonic vibration to welding clamp, welding clamp is used for placing tool handle and tool head, pressure mechanism is installed on vertical plate, and pressure mechanism is used for exerting pressure to tool handle on welding clamp.

2. The micro-tool ultrasonic-assisted welding apparatus of claim 1, wherein: The ultrasonic vibration mechanism includes a housing, an ultrasonic power supply, a transducer, and an ultrasonic amplitude transformer. The transducer is installed in the housing, the housing is fixedly connected with the base, the ultrasonic power supply is electrically connected with the transducer, the transducer is installed in the housing, one end of the ultrasonic amplitude transformer is connected with the transducer, and the other end of the ultrasonic amplitude transformer is fixedly connected with the welding clamp.

3. The micro-tool ultrasonic-assisted welding apparatus of claim 2, wherein: The transducer includes a back cover plate, a piezoelectric ceramic sheet, and a copper electrode. The piezoelectric ceramic and the copper electrode are sequentially stacked between the back cover plate and the ultrasonic amplitude transformer. The back cover plate, the piezoelectric ceramic sheet, the copper electrode, and the ultrasonic amplitude transformer are threadedly connected by bolts. The piezoelectric ceramic is electrically connected with the ultrasonic power supply through the copper electrode.

4. The micro-tool ultrasonic-assisted welding apparatus of claim 2, wherein: The number of ultrasonic vibration mechanisms is two, and the two ultrasonic vibration mechanisms are uniformly distributed at the bottom of the welding clamp.

5. The micro-tool ultrasonic-assisted welding apparatus of claim 1, wherein: The cross section of the welding clamp is H-shaped. The welding clamp includes a top plate, a bottom plate, and a connecting plate. The top plate is connected with the bottom plate through the connecting plate. The top plate and the bottom plate are parallel to each other and have the same size. A plurality of through holes for placing tool handles are formed in the top plate. A plurality of blind holes for placing tool heads corresponding to the through holes are formed in the bottom plate.

6. The micro-tool ultrasonic-assisted welding apparatus of claim 5, wherein: The cooperation gap between the through hole and the tool handle is 0.01-0.03 mm, and the cooperation gap between the blind hole and the tool head is 0.01-0.03 mm.

7. The micro-tool ultrasonic-assisted welding apparatus of claim 1, wherein: The mounting frame further includes a horizontal plate. The horizontal plate is fixedly connected with one end of the vertical plate away from the base. The vertical plate has vertical sliding rails. The pressure mechanism includes a driving device, a sliding block, and a pressure plate. The driving device is fixedly installed on the horizontal plate. The output end of the driving device is fixedly connected with the pressure plate. The pressure plate is fixedly connected with the sliding block. The sliding block is connected with the sliding rails. The driving device drives the pressure plate to move up and down to exert pressure on the tool handle.

8. The micro-tool ultrasonic-assisted welding apparatus of claim 7, wherein: The driving device is a pneumatic cylinder.

9. The micro-tool ultrasonic-assisted welding apparatus of claim 1, wherein: The end face of the tool handle and the tool head is provided with a first groove, and the end face of the tool head and the tool handle is provided with a second groove.

10. A method of ultrasonic-assisted welding of a microcutter using the apparatus of any one of claims 1-9, characterized in that: The method includes the following steps: Step one, place the tool handle and the tool head on the welding clamp, and fill the flux between the tool head and the tool handle; Step two, use the pressure mechanism to exert a certain pressure on the tool handle, and at the same time, use the welding device to weld the tool handle and the tool head, so that the flux is converted into a molten state. At the same time, start the ultrasonic vibration mechanism to generate high-frequency vibration on the welding clamp. The welding clamp drives the tool handle and the tool head to vibrate, so that the flux is uniformly distributed in the gap between the tool head and the tool handle, until the tool head and the tool handle are welded.

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