Ultrasonic-assisted continuous blanking forming method and system for amorphous alloy strip

Abstract

The invention provides an ultrasonic-assisted continuous blanking forming method and system for an amorphous alloy strip, and relates to the technical field of amorphous alloy machining. According to the ultrasonic-assisted continuous blanking forming method for the amorphous alloy strip, through technical cooperation of two core procedures of ultrasonic softening treatment and blanking treatment, on the premise that no auxiliary material is added and excellent soft magnetic performance of amorphous alloy is reserved, blanking force is reduced, die abrasion is reduced, and machining precision and production efficiency are improved. According to the ultrasonic-assisted continuous blanking forming system for the amorphous alloy strip, the feeding device, the ultrasonic pretreatment unit, the conveying device and the blanking treatment unit are arranged in series along the strip conveying path, the feeding device continuously supplies materials, the conveying device is seamlessly connected with softening and blanking links, and the control unit overall regulates and controls the operation rhythm of all the units, so that the continuous blanking forming of the amorphous alloy strip is achieved. And the strip is continuously transferred in the whole process, the industrial large-scale production requirement is met, and the overall machining efficiency is remarkably improved.

Description

Technical Field

[0001] This invention relates to the field of amorphous alloy processing technology, specifically to an ultrasonic-assisted continuous punching forming method and system for amorphous alloy strips. Background Technology

[0002] Amorphous alloys, with their unique structure of disordered atomic arrangement, exhibit a series of excellent mechanical and functional properties, including high strength, high hardness, excellent corrosion resistance, and outstanding soft magnetic properties, making them promising for applications in power electronics, precision devices, aerospace, and new energy fields. Among these, amorphous alloy strips, as a core material for manufacturing energy-saving transformer cores, motor cores, and high-end inductors and instrument transformers, have their efficient and precise processing quality directly affecting the performance and cost of downstream products.

[0003] With the rapid development of high-end equipment such as electric drive spindle motors for new energy vehicles and industrial air compressor motors towards higher efficiency, miniaturization, and lightweighting, more stringent requirements have been placed on the processing of core components, such as iron cores. First, the excellent soft magnetic properties of the amorphous alloy itself must be fully preserved, avoiding damage to the material's atomic structure during processing. Second, high-precision forming of complex structures is required to meet the demands of precision assembly and operational stability. Third, the efficiency requirements of large-scale production must be matched while controlling processing costs. Currently, conventional machining methods for amorphous alloy laminated iron cores mainly involve shearing, polishing, and wire cutting, but these methods reveal many insurmountable limitations when addressing the demands of high-end applications.

[0004] Taking the critical jaw structure of a motor core as an example, shearing is limited by the cutting tools, making it difficult to achieve high-precision, complex shapes for the jaws. It easily produces defects such as burrs and edge collapse, and cannot adapt to continuous multi-station forming, often requiring subsequent polishing, which is cumbersome and inefficient. Polishing is only suitable for improving surface roughness and cannot complete structural forming, so it can only be used as an auxiliary process. While wire EDM can process certain complex shapes, its processing efficiency is extremely low, as it is a point-by-point etching process, making it difficult to meet the pace of mass production. Furthermore, it is costly, energy-intensive, and requires highly skilled operators. In addition, the heat-affected zone generated during wire EDM may damage the amorphous structure of amorphous alloys, leading to a decrease in soft magnetic properties and introducing defects such as microcracks, affecting the reliability and lifespan of the core. Regarding forming accuracy, wire EDM has limited control over fine structures such as tiny fillets, easily resulting in dimensional deviations and surface quality issues.

[0005] Therefore, developing an efficient, high-precision, and low-cost amorphous alloy strip stamping / blanking technology, similar to processing silicon steel sheets, has become an urgent industry need. Stamping technology, through one-time forming with a die, can achieve high-precision and consistent processing of complex structures, with efficiency far exceeding wire cutting. Furthermore, as a cold working process, it helps maintain the atomic structure and soft magnetic properties of amorphous alloys. Simultaneously, the simple stamping process and long die life contribute to reduced production costs. However, the inherent low plasticity and high brittleness of amorphous alloys at room temperature present challenges in traditional blanking processes, including high blanking forces, rapid die wear, and the tendency for micro-cracks or even fractures at the workpiece cut, severely restricting their high-quality, continuous production.

[0006] Existing amorphous alloy blanking technologies employ ultrasonic-assisted blanking, such as Chinese patent document CN108246861A. However, this requires the addition of polymer particles during the blanking process to improve the stress state. This not only increases material costs and subsequent cleaning processes but may also affect workpiece performance due to particle residue. Therefore, there is an urgent need to develop an integrated ultrasonic-assisted blanking forming technology that can efficiently, precisely, and with low die wear produce amorphous alloys that maintain excellent soft magnetic properties without the need for auxiliary materials, thus overcoming the shortcomings of existing technologies. Summary of the Invention

[0007] To address the shortcomings of existing technologies, this invention provides an ultrasonic-assisted continuous punching forming method and system for amorphous alloy strips. The ultrasonic-assisted continuous punching forming method for amorphous alloy strips can significantly reduce punching force and die wear, and improve processing accuracy and production efficiency, while maintaining the excellent soft magnetic properties of amorphous alloys and without adding auxiliary materials.

[0008] The specific technical solution of this invention is as follows:

[0009] In a first aspect, the present invention provides an ultrasonic-assisted continuous punching forming method for amorphous alloy strips, comprising the following steps: S1. Ultrasonic softening treatment: The amorphous alloy strip is continuously conveyed to the ultrasonic pretreatment unit, ultrasonic waves are applied to the amorphous alloy strip to soften it, and the ultrasonic contact stress is controlled to be less than the yield strength of the amorphous alloy strip, so that the amorphous alloy strip on the ultrasonic softening treatment radiation surface is softened. S2. Blanking process: The amorphous alloy strip after ultrasonic softening in step S1 is continuously conveyed to the blanking process unit through a conveying device, so that the center of the ultrasonic softening area of ​​the amorphous alloy strip is aligned with the center of the blanking area of ​​the blanking process unit, and then continuous blanking is performed.

[0010] In one possible implementation, the amorphous alloy strip is composed of one of iron-based amorphous alloys, zirconium-based amorphous alloys, copper-based amorphous alloys, nickel-based amorphous alloys, iron-cobalt-based amorphous alloys, iron-zirconium-based amorphous alloys, copper-zirconium-based amorphous alloys, and iron-copper-based amorphous alloys.

[0011] In one possible implementation, the composition of the amorphous alloy strip is selected from Fe. 80 Si9B 11 Fe 78 Si 10 B 12 Fe 77.5 Si9B 12 Nb 1.5 Zr 56 Cu 28 Al 10 Ni6, Zr 65 Cu 17.5 Al 10 Ni 7.5 Zr 62 Cu 20 Al 10 Ag8, Cu 50 Zr 42 Al8, Cu 56 Zr 36 Al8, Cu 54 Zr 36 Al8Hf2, Ni 78 Si 10 B 12 Ni 75 Cr5P 16 B4, Ni 60 Fe 20 P 14 B6, Ni 45 Co 25 Fe5P 18 B7, (Fe 0.94 Co 0.06 ) 78 Si 10 B 12 Fe 72 Co6Si 10 B 12 Co 66 Fe4Ni2Si 10 B 16 Co 71 Fe4MoSi 10 B 14 、(Fe 0.95 Zr 0.05 ) 80 B 20 Fe76 Zr4B 20 、(Fe 0.65 Zr 0.35 ) 96 B 24 Cu 50 Zr 43 Al7, Cu 56 Zr 34 Ti 10 Cu 48 Zr 44 Al8Ag5, (Fe 0.8 Cu 0.2 ) 78 Zr2B 20 Fe 81 Si 3.5 B 13.5 C2, Fe 70 Cu 10 Zr5B 15 and (Fe 0.92 Cu 0.08 ) 79.5 Si 10 B9Nb 1.5 One of them.

[0012] In one possible implementation, the frequency of the ultrasonic wave in step S1 is 10 kHz to 100 kHz, the amplitude is 10 to 50 μm, and the ultrasonic softening time is 1 to 10 s.

[0013] In one possible implementation, the ultrasonic contact stress in step S1 is 0.05-0.3 GPa.

[0014] In one possible implementation, in step S2, the corresponding deviation between the center of the ultrasonic softening region and the center of the punching region is ≤0.1 mm, the length of the ultrasonic softening region is greater than the length of the punching region, and the width of the ultrasonic softening region is greater than the width of the punching region.

[0015] Furthermore, the length of the ultrasonic softening region is 2-20 mm longer than the length of the punching region, and the width of the ultrasonic softening region is 2-20 mm wider than the width of the punching region.

[0016] In one possible implementation, the conveying positioning accuracy of the conveying device is ±0.01 mm.

[0017] In a second aspect, the present invention provides an ultrasonic-assisted continuous punching forming system for amorphous alloy strips, comprising: An ultrasonic pretreatment unit is used to apply ultrasonic waves to amorphous alloy strips for ultrasonic softening. A feeding device is provided at the feed end of the ultrasonic pretreatment unit for continuously feeding amorphous alloy strips into the ultrasonic pretreatment unit. A punching unit is provided at the discharge end of the ultrasonic pretreatment unit for continuously punching and forming the ultrasonically softened amorphous alloy strip. A conveying device is disposed on the conveying path of the amorphous alloy strip, for continuously and accurately conveying the amorphous alloy strip from the ultrasonic pretreatment unit to the punching unit, and aligning the ultrasonically softened area of ​​the amorphous alloy strip with the punching area of ​​the punching unit. The control unit is electrically connected to the ultrasonic pretreatment unit, the punching unit, and the conveying device, and is used to coordinate the control of the ultrasonic pretreatment, conveying, and punching processes.

[0018] In one possible implementation, the ultrasonic pretreatment unit and the blanking unit are located within the same support frame. The support frame is divided into an ultrasonic pretreatment area and a blanking area by a partition plate. The ultrasonic pretreatment unit is located in the ultrasonic pretreatment area, and the blanking unit is located in the blanking area. A strip channel is provided on the partition plate, through which the amorphous alloy strip can enter the blanking area from the ultrasonic pretreatment area.

[0019] In one possible implementation, the ultrasound pretreatment unit includes: An ultrasonic component, including an ultrasonic indenter, an ultrasonic transducer, and an ultrasonic generator, is used to apply ultrasonic vibrations to the amorphous alloy strip; the ultrasonic indenter is positioned above the area of ​​the amorphous alloy strip to be ultrasonically softened, and the vibration output end of the ultrasonic transducer is rigidly connected to the ultrasonic indenter; the ultrasonic generator is electrically connected to the ultrasonic transducer. A lifting mechanism is located directly above the ultrasonic pressure head and the ultrasonic transducer, used to drive the lifting movement of the ultrasonic pressure head and the ultrasonic transducer, with its upper end fixed on the support frame and its lower end rigidly connected to the ultrasonic transducer. The first sensor, embedded in the pressure end of the ultrasonic indenter, is used to detect the ultrasonic contact stress applied by the ultrasonic indenter to the amorphous alloy strip and the center position of the ultrasonic softening region. The ultrasonic generator, the lifting mechanism, and the first sensor are also electrically connected to the control unit.

[0020] In one possible implementation, the punching processing unit includes: A punch is positioned directly above the punching area and is used to perform punching processing on the amorphous alloy strip; The lower die is located directly below the punching area and is installed on the worktable in the middle of the support frame. It works with the punch to punch the amorphous alloy strip. A punching drive mechanism is located above the punch, with its upper end fixed to the top of the support frame. Its power output end is rigidly connected to the punch and is used to drive the punch to move up and down. The second sensor is located below the blanking area and installed at the lower end of the lower die, and is used to detect the center position of the blanking area. The punching drive mechanism and the second sensor are respectively electrically connected to the control unit.

[0021] The positive and progressive effects of this invention are as follows: This invention provides an ultrasonic-assisted continuous punching forming method and system for amorphous alloy strips. The ultrasonic-assisted continuous punching forming method for amorphous alloy strips achieves reduced punching force, reduced die wear, and improved processing accuracy and production efficiency through the synergistic operation of two core processes: ultrasonic softening treatment and punching treatment. This is done without adding any auxiliary materials and while fully preserving the excellent soft magnetic properties of the amorphous alloy. The ultrasonic-assisted continuous punching forming system for amorphous alloy strips arranges a feeding device, an ultrasonic pretreatment unit, a conveying device, and a punching treatment unit in series along the strip conveying path. The feeding device continuously supplies material, the conveying device seamlessly connects the softening and punching stages, and the control unit coordinates the operation rhythm of each unit, ensuring continuous strip flow throughout the process. This eliminates the need for offline transfer, manual intervention, or frequent equipment start-ups and shutdowns, perfectly adapting to the needs of large-scale industrial production and significantly improving overall processing efficiency. This system relies on the softening effect of the ultrasonic pretreatment unit to significantly reduce the macroscopic deformation resistance of the amorphous alloy strip. The blanking unit can complete the forming under low blanking force, which not only reduces the power consumption and operating load of the blanking equipment, but also significantly weakens the shear friction and impact between the die and the strip, effectively reducing the die wear rate, extending the die service life, and reducing the cost and frequency of die replacement and maintenance. Attached Figure Description

[0022] Figure 1 The image shows a comparison of X-ray diffraction patterns of the amorphous alloy strips before and after ultrasonic punching in Example 1.

[0023] Figure 2 The images show a comparison of the surface morphology of the amorphous alloy strip before and after ultrasonic punching in Example 1 using atomic force microscopy.

[0024] Figure 3 This is a comparison of the surface roughness of the amorphous alloy strip before and after ultrasonic punching in Example 1.

[0025] Figure 4This is a comparison diagram of the mechanical properties of the amorphous alloy strip before and after ultrasonic punching in Example 1.

[0026] Figure 5 This is a comparison chart of the wear rate of the punching die before and after ultrasonic punching in Example 1.

[0027] Figure 6 This is a comparison diagram of the punching force before and after ultrasonic punching in Example 1.

[0028] Figure 7 This is a schematic diagram of the ultrasonic-assisted continuous punching forming system for amorphous alloy strips provided in Example 10.

[0029] Figure Labels 1-Feeding device, 2-Ultrasonic pretreatment unit, 3-Transfer device, 4-Blanking processing unit, 5-Unloading mechanism, 6-Control unit, 7-Support frame, 8-Amorphous alloy strip, 9-Electrical control cabinet, 11-Brake wheel, 12-Idler wheel, 21-Ultrasonic component, 22-Lifting mechanism, 23-First sensor, 31-Active roller, 32-Pressure roller, 33-Guide roller, 34-Adjustable bearing seat, 41-Punch, 42-Lower die, 43-Blanking drive mechanism, 44-Second sensor, 51-Rewinding roller, 52-Unloading plate, 53-Receiving box, 71-Separator plate, 72-Workbench, 211-Ultrasonic pressure head, 212-Ultrasonic transducer, 213-Ultrasonic generator. Detailed Implementation

[0030] To make the above-mentioned objects, features, and advantages of the present invention more apparent and understandable, specific embodiments of the present invention are described in detail below. It should be noted that the following embodiments are only used to illustrate the implementation methods and typical parameters of the present invention, and are not intended to limit the parameter range described in the present invention. Reasonable variations derived therefrom are still within the protection scope of the present invention.

[0031] It should be noted that the endpoints and any values ​​of the ranges disclosed herein are not limited to the precise ranges or values, and these ranges or values ​​should be understood to include values ​​close to these ranges or values. For numerical ranges, the endpoint values ​​of the various ranges, the endpoint values ​​of the various ranges and individual point values, and individual point values ​​can be combined with each other to obtain one or more new numerical ranges, which should be considered as specifically disclosed herein.

[0032] Unless otherwise defined, all terms, symbols, and other scientific terms used herein are intended to have the same meaning as commonly understood by one of ordinary skill in the art to which this invention pertains. In some instances, terms having a conventional meaning are defined herein for clarification or ease of reference, and such definitions should not be construed as indicating a significant difference from conventional understanding in the art. The technical methods described or referenced herein are generally well understood by those skilled in the art and employed by conventional methods. Unless otherwise stated, the use of commercially available kits, reagents, and instruments shall be performed according to the manufacturer's instructions and parameters.

[0033] Terminology Explanation: Ultrasonic contact stress: In this invention, ultrasonic contact stress refers to the static or quasi-static vertical pressure applied by the ultrasonic indenter to maintain stable contact with the surface of the amorphous alloy strip when ultrasonic vibration is applied.

[0034] The specific technical solution of this invention is as follows: In a first aspect, the present invention provides an ultrasonic-assisted continuous punching forming method for amorphous alloy strips, comprising the following steps: S1. Ultrasonic softening treatment: The amorphous alloy strip is continuously conveyed to the ultrasonic pretreatment unit, ultrasonic waves are applied to the amorphous alloy strip to soften it, and the ultrasonic contact stress is controlled to be less than the yield strength of the amorphous alloy strip, so that the amorphous alloy strip on the ultrasonic softening treatment radiation surface is softened. Step S1 applies ultrasonic vibration to the amorphous alloy strip, using ultrasonic energy to induce short-range ordered structural relaxation (local atomic rearrangement) in the amorphous alloy strip, reducing its modulus and hardness. This significantly reduces the resistance to plastic deformation in the blanking area of ​​the amorphous alloy strip, achieving "controllable softening." This fundamentally reduces the difficulty of blanking the amorphous alloy strip, making continuous blanking forming a feasible process. Controlling the ultrasonic contact stress to be less than the yield strength of the amorphous alloy strip ensures that the ultrasonic energy is transmitted under purely elastic contact conditions. The indenter and the strip only achieve tight coupling to transmit vibration, without producing macroscopic plastic deformation, indentation, or surface damage. Simultaneously, this energy input level does not induce a crystallization transformation of the amorphous structure. Step S1 achieves softening while perfectly preserving the excellent original properties of the amorphous alloy.

[0035] S2. Blanking process: The amorphous alloy strip after ultrasonic softening in step S1 is continuously conveyed to the blanking process unit through a conveying device, so that the center of the ultrasonic softening area of ​​the amorphous alloy strip is aligned with the center of the blanking area of ​​the blanking process unit, and then continuous blanking is performed.

[0036] Step S2 involves continuously conveying the amorphous alloy strip, which has been ultrasonically softened in step S1, to the blanking unit via a conveying device, thus establishing a continuous process path of "ultrasonic softening - blanking." The continuous conveying characteristic of the conveying device avoids processing interruptions caused by offline transfer, adapts to the needs of continuous industrial production, and precisely inherits the softening effect of step S1, ensuring that the strip enters the blanking stage before the softened state dissipates, thus maximizing the effect of ultrasonic softening in reducing blanking force.

[0037] The ultrasonic-assisted continuous punching forming method for amorphous alloy strips provided by this invention achieves reduced punching force, decreased die wear, and improved processing accuracy and production efficiency through the synergistic application of two core processes: ultrasonic softening treatment and punching treatment. This is done without adding any auxiliary materials and while fully preserving the excellent soft magnetic properties of the amorphous alloy. The soft magnetic properties of amorphous alloys depend on their "long-range disorder, short-range order" amorphous structure; crystallization, structural defects, and plastic deformation all lead to the deterioration of soft magnetic properties. By controlling the ultrasonic contact stress to be less than the yield strength of the amorphous alloy strip, softening is achieved only through short-range relaxation of the amorphous structure induced by ultrasonic vibration. The ultrasonic energy acts only on the surface area of ​​the strip to be punched, ensuring the stability of the overall amorphous structure of the strip and thus fully preserving its excellent soft magnetic properties. The high hardness and high modulus of amorphous alloys are the core reasons for excessive punching force. By inducing short-range relaxation of the amorphous structure through ultrasonic vibration, the modulus and hardness of the strip are significantly reduced, greatly decreasing the resistance to plastic deformation in the area to be punched. By eliminating the need for additional lubricating materials to reduce friction, the punching force can be significantly reduced, simplifying the process and avoiding the contamination of the strip surface by residual materials that could affect its soft magnetic properties. The punching force of the strip after ultrasonic softening is greatly reduced, and the shear friction and impact load between the die and the strip are simultaneously weakened, reducing die edge wear at its source. Precise transport via a conveyor device aligns the center of the ultrasonic softening area with the center of the punching area, ensuring that the punching force acts only on the softened strip area. This avoids defects such as cracking and chipping in the non-softened areas due to excessive force, and utilizes the low deformation resistance of the softened area to obtain a smooth punched cross-section and accurate workpiece dimensions, improving the processing accuracy and yield of the formed parts. The continuous process path of "conveyor-softening-punching" eliminates the need for frequent start-stop operations for positioning and workpiece handling compared to traditional intermittent punching, significantly shortening the processing cycle and improving production efficiency.

[0038] In one possible implementation, the amorphous alloy strip is selected from one of the following: iron-based amorphous alloys, zirconium-based amorphous alloys, copper-based amorphous alloys, nickel-based amorphous alloys, iron-cobalt-based amorphous alloys, iron-zirconium-based amorphous alloys, copper-zirconium-based amorphous alloys, and iron-copper-based amorphous alloys. All of these amorphous alloys possess a typical amorphous structure characterized by "long-range disorder and short-range order," with interatomic binding energies within a moderate range. They can all effectively induce short-range structural relaxation through ultrasonic vibration, achieving controllable softening.

[0039] In one possible implementation, the composition of the amorphous alloy strip is selected from Fe. 80 Si9B 11 Fe 78 Si 10 B 12 Fe 77.5 Si9B 12 Nb 1.5 Zr 56 Cu 28 Al 10 Ni6, Zr 65 Cu 17.5 Al 10 Ni 7.5 Zr 62 Cu 20 Al 10 Ag8, Cu 50 Zr 42 Al8, Cu 56 Zr 36 Al8, Cu 54 Zr 36 Al8Hf2, Ni 78 Si 10 B 12 Ni 75 Cr5P 16 B4, Ni 60 Fe 20 P 14 B6, Ni 45 Co 25 Fe5P 18 B7, (Fe 0.94 Co 0.06 ) 78 Si 10 B 12 Fe 72 Co6Si 10 B 12 Co 66 Fe4Ni2Si 10 B 16 Co 71 Fe4MoSi 10 B 14 、(Fe 0.95 Zr 0.05 ) 80 B 20 Fe 76 Zr4B 20 、(Fe 0.65 Zr 0.35 ) 96 B 24 Cu 50 Zr43 Al7, Cu 56 Zr 34 Ti 10 Cu 48 Zr 44 Al8Ag5, (Fe 0.8 Cu 0.2 ) 78 Zr2B 20 Fe 81 Si 3.5 B 13.5 C2, Fe 70 Cu 10 Zr5B 15 and (Fe 0.92 Cu 0.08 ) 79.5 Si 10 B9Nb 1.5 One of them. The amorphous alloy strips composed of the above have excellent amorphous forming ability, with an amorphous structure of "long-range disorder and short-range order", and no obvious crystalline phase precipitation; the processing technology of various components is highly compatible, and compatible processing can be achieved on the same production line without the need to modify equipment or adjust the process system for different components, which greatly reduces the equipment debugging cost, process control difficulty and raw material procurement cost of large-scale production, and significantly improves the industrialization feasibility of the overall technical solution.

[0040] In one possible implementation, the frequency of the ultrasound in step S1 is 10 kHz to 100 kHz, the amplitude is 10 to 50 μm, and the ultrasonic softening time is 1 to 10 s. The ultrasound with a frequency of 10 kHz to 100 kHz lays the foundation for efficient energy transfer, ensuring that energy is precisely coupled into the alloy to induce local atomic motion; the 10 to 50 μm amplitude provides the mechanical driving force for the local "viscous flow" of the atomic structure; the 1 to 10 s softening time adapts to the energy output rhythm of the former two, and can be flexibly adjusted for different alloy compositions to ensure that the atomic structure completes sufficient relaxation without spontaneous crystallization.

[0041] In one possible implementation, the ultrasonic contact stress in step S1 is 0.05-0.3 GPa. This ultrasonic contact stress of 0.05-0.3 GPa is far lower than the yield strength of commonly used amorphous alloys, ensuring the overall stability of the amorphous structure of the amorphous alloy strip.

[0042] In one possible implementation, in step S2, the corresponding deviation between the center of the ultrasonically softened region and the center of the punching region is ≤0.1 mm, the length of the ultrasonically softened region is greater than the length of the punching region, and the width of the ultrasonically softened region is greater than the width of the punching region. Limiting the corresponding deviation between the center of the ultrasonically softened region and the center of the punching region to ≤0.1 mm ensures that the ultrasonically softened region, which has undergone ultrasonic-induced atomic rearrangement and reduced deformation resistance, can achieve sub-millimeter-level spatial overlap with the punching region after transmission. Limiting the size of the ultrasonically softened region to be greater than the size of the punching region creates a "softening allowance," which can compensate for minor positioning fluctuations during continuous transport, ensuring that the punching edge is also in a softened state.

[0043] Furthermore, the length of the ultrasonic softening region is 2-20 mm longer than the length of the punching region, and the width of the ultrasonic softening region is 2-20 mm wider than the width of the punching region. This 2-20 mm length and width allowance ensures that the punching force is applied evenly to the ultrasonic softening region.

[0044] In one possible implementation, the conveying positioning accuracy of the conveying device is ±0.01 mm. Limiting the conveying positioning accuracy of the conveying device to ±0.01 mm enables precise and continuous conveying of the amorphous alloy strip, ensuring accurate alignment between the ultrasonically softened area and the center of the punching area.

[0045] In a second aspect, the present invention provides an ultrasonic-assisted continuous punching forming system for amorphous alloy strips, comprising: An ultrasonic pretreatment unit is used to apply ultrasonic waves to amorphous alloy strips for ultrasonic softening. A feeding device is provided at the feed end of the ultrasonic pretreatment unit for continuously feeding amorphous alloy strips into the ultrasonic pretreatment unit. A punching unit is provided at the discharge end of the ultrasonic pretreatment unit for continuously punching and forming the ultrasonically softened amorphous alloy strip. A conveying device is disposed on the conveying path of the amorphous alloy strip, for continuously and accurately conveying the amorphous alloy strip from the ultrasonic pretreatment unit to the punching unit, and aligning the ultrasonically softened area of ​​the amorphous alloy strip with the punching area of ​​the punching unit. The control unit is electrically connected to the ultrasonic pretreatment unit, the punching unit, and the conveying device, and is used to coordinate the control of the ultrasonic pretreatment, conveying, and punching processes.

[0046] This invention provides an ultrasonic-assisted continuous punching forming system for amorphous alloy strips. By arranging a feeding device, an ultrasonic pretreatment unit, a conveying device, and a punching unit in series along the conveying path of the amorphous alloy strip, the feeding device continuously supplies material, the conveying device seamlessly connects the softening and punching stages, and the control unit coordinates and regulates the operating rhythm of each unit, enabling the amorphous alloy strip to flow continuously throughout the entire process. This eliminates the need for offline transfer, manual intervention, or frequent equipment start-ups and shutdowns, perfectly adapting to the needs of large-scale industrial production and significantly improving overall processing efficiency. Utilizing the softening effect of the ultrasonic pretreatment unit, the macroscopic deformation resistance of the amorphous alloy strip is significantly reduced, allowing the punching unit to complete forming under low punching force. This not only reduces the power consumption and operating load of the punching equipment but also significantly weakens the shear friction and impact between the die and the amorphous alloy strip, effectively reducing the die wear rate.

[0047] In one possible implementation, the ultrasonic pretreatment unit and the blanking unit are located within the same support frame. The support frame is divided into an ultrasonic pretreatment area and a blanking area by a partition plate. The ultrasonic pretreatment unit is located in the ultrasonic pretreatment area, and the blanking unit is located in the blanking area. A strip channel is provided on the partition plate, through which the amorphous alloy strip can enter the blanking area from the ultrasonic pretreatment area.

[0048] The ultrasonic pretreatment unit and the blanking unit are integrated into the same support frame. The partitioned layout effectively isolates the blanking vibration and impact load in the blanking area, preventing them from being transmitted to the ultrasonic pretreatment area. The strip channel on the partition allows the two core units to be seamlessly connected along the amorphous alloy strip conveying path. Together with the feeding and conveying devices, a compact process link of "feeding-softening-blading" is formed, which meets the spatial layout requirements of continuous production. At the same time, it also significantly reduces the overall footprint of the equipment and avoids the spatial redundancy of decentralized installation.

[0049] In one possible implementation, the ultrasound pretreatment unit includes: An ultrasonic component, including an ultrasonic indenter, an ultrasonic transducer, and an ultrasonic generator, is used to apply ultrasonic vibrations to the amorphous alloy strip; the ultrasonic indenter is disposed above the ultrasonic softening region of the amorphous alloy strip, and the vibration output end of the ultrasonic transducer is rigidly connected to the ultrasonic indenter; the ultrasonic generator is electrically connected to the ultrasonic transducer. A lifting mechanism is located directly above the ultrasonic pressure head and the ultrasonic transducer, used to drive the lifting movement of the ultrasonic pressure head and the ultrasonic transducer, with its upper end fixed on the support frame and its lower end rigidly connected to the ultrasonic transducer. The first sensor is embedded in the pressure end of the ultrasonic indenter and is used to detect the ultrasonic contact stress applied by the ultrasonic indenter to the amorphous alloy strip and the center position of the ultrasonic softening region. The ultrasonic generator, the lifting mechanism, and the first sensor are also electrically connected to the control unit.

[0050] The ultrasonic components of the ultrasonic pretreatment unit employ a rigid and electrically connected approach between the ultrasonic indenter, ultrasonic transducer, and ultrasonic generator. The ultrasonic indenter is precisely positioned to correspond to the ultrasonic softening area, achieving efficient, directional, and stable transmission of ultrasonic energy and ensuring precise local softening of the amorphous alloy strip. The lifting mechanism is fixed at its upper end to the support frame and rigidly connected to the ultrasonic transducer at its lower end. This ensures the stability of the lifting motion, drives the ultrasonic indenter to rise and fall to accommodate amorphous alloy strips of different thicknesses, and provides a mechanical basis for ultrasonic contact stress control. The first sensor is embedded in the pressure-applying end of the ultrasonic indenter, enabling direct, real-time, and high-precision detection of ultrasonic contact stress, providing reliable data support for stress control. The ultrasonic generator, lifting mechanism, and first sensor are all electrically connected to the control unit, constructing a closed-loop control system of "detection-feedback-control." This system accurately controls the ultrasonic contact stress within a preset range, automatically adapts to the softening requirements of different alloy compositions, and avoids structural damage to the amorphous alloy strip to preserve its core performance.

[0051] In one possible implementation, the punching processing unit includes: A punch is positioned directly above the punching area and is used to perform punching processing on the amorphous alloy strip; The lower die is located directly below the punching area and is installed on the worktable in the middle of the support frame. It works with the punch to punch the amorphous alloy strip. A punching drive mechanism is located above the punch, with its upper end fixed to the top of the support frame. Its power output end is rigidly connected to the punch and is used to drive the punch to move up and down. The second sensor is located below the blanking area and installed at the lower end of the lower die, and is used to detect the center position of the blanking area. The punching drive mechanism and the second sensor are respectively electrically connected to the control unit.

[0052] The blanking processing unit has the advantages of stable structure, accurate blanking, and strong adaptability through the precise layout of the punch, lower die, blanking drive mechanism, and second sensor, as well as the linkage design with the control unit. The punch and lower die are arranged vertically along the blanking area. The lower die is fixed to the worktable in the middle of the frame. The upper end of the blanking drive mechanism is fixed to the top of the frame, and the power output end is rigidly connected to the punch. This ensures the smoothness of the punch's lifting and lowering movement and the efficient transmission of blanking force by relying on the rigidity of the frame. It can also be adapted to the low deformation resistance strip after ultrasonic softening, thus achieving low-force and precise blanking. The second sensor is installed on the support frame and aligned with the lower part of the blanking area. It can detect the center position of the blanking area in real time and provide accurate positioning data for the control unit. This works in conjunction with the high-precision conveying of the conveying device and the alignment requirements of the ultrasonic softening area. The control unit regulates the blanking drive mechanism and the conveying device to correct minor positioning deviations and ensure that the blanking area and the ultrasonic softening area fit precisely. The overall structure is integrated into the blanking processing area of ​​the frame. With the help of the partition plate for vibration isolation and interference resistance, it improves the stability of operation. The components are neatly arranged and reliably connected. This reduces die wear, ensures blanking accuracy and product consistency, and facilitates maintenance, adapting to the needs of continuous production.

[0053] The technical solution of the present invention will be further described below with reference to specific embodiments and comparative examples. All reagents used in the embodiments are commercially available or synthesized by conventional methods and can be used directly without further processing. The instruments used in the embodiments are also commercially available.

[0054] Example 1 This embodiment provides an ultrasonic-assisted continuous punching forming method for iron-based amorphous alloy strips, including the following steps: S1. Ultrasonic softening treatment: S1.1 Preparation of the strip: Select an iron-based amorphous alloy strip with a width of 100 mm and a thickness of 0.1 mm as the raw material. The composition of the iron-based amorphous alloy strip is Fe. 80 Si9B 11 The iron-based amorphous alloy strip has a yield strength of 1.6 GPa, an elastic strain limit of 2%, and a tensile strength of 1500 MPa. S1.2 Softening Treatment: The iron-based amorphous alloy strip is continuously fed to the ultrasonic pretreatment unit at a feed rate of 1.2 m / min and a tension of 80 N. The size of the radiation surface for ultrasonic softening treatment is 50 mm × 30 mm. Ultrasonic vibration is started at a frequency of 28 kHz and an amplitude of 30 μm. The ultrasonic softening time is 1.5 s, and the ultrasonic contact stress is 0.1 GPa (6.25% of the yield strength, corresponding to an elastic strain of 0.067%). This locally softens the amorphous alloy strip. S2, Blanking process: S2.1 Precise transmission: The iron-based amorphous alloy strip that has undergone ultrasonic softening treatment in step S1 is continuously transported to the blanking unit through a conveying device. The size of the blanking workpiece is 45 mm × 25 mm. The conveying step distance of the conveying device is equal to the distance between the center of the ultrasonic softening area and the center of the blanking area, so that the iron-based amorphous alloy strip is precisely moved from the ultrasonic pretreatment area to the blanking area, and the corresponding deviation between the center of the ultrasonic softening area and the center of the blanking area is controlled to be ≤0.1 mm. S2.2 Continuous punching: When the iron-based amorphous alloy strip reaches the punching position, punching is started with a punching force of 15 kN and a punching speed of 0.5 mm / s. After a single punching is completed, the conveying device continues to transport the iron-based amorphous alloy strip to the next "ultrasonic softening treatment-punching treatment" cycle, so as to realize the continuous processing of the iron-based amorphous alloy strip.

[0055] The blanking force used in this embodiment is 15 kN, while the blanking force for conventional cold blanking of the same iron-based amorphous alloy strip is 31.2 kN. The blanking force used in this embodiment is only 48% of that of conventional cold blanking. Testing showed that both the samples before and after ultrasonication were amorphous, and ultrasonic treatment did not significantly affect the surface quality. The modulus and hardness of the amorphous alloy after ultrasonication were lower than before ultrasonication. The wear rate of the blanking die was 0.025 mm / 10,000 cycles, a decrease of approximately 62.5% compared to blanking without ultrasonication. The blanking force decreased by approximately 51.9%, and the product qualification rate was 96%.

[0056] Example 2 This embodiment provides an ultrasonic-assisted continuous punching forming method for zirconium-based amorphous alloy strips, including the following steps: S1. Ultrasonic softening treatment: S1.1 Preparation of the strip: A zirconium-based amorphous alloy strip with a width of 80 mm and a thickness of 0.08 mm is selected as the raw material. The zirconium-based amorphous alloy strip is composed of Zr. 56 Cu 28 Al 10 The yield strength of Ni6 zirconium-based amorphous alloy strip is 1.5 GPa, the elastic strain limit is 1.8%, and the tensile strength is 1400 MPa. S1.2 Softening Treatment: The zirconium-based amorphous alloy strip is continuously fed to the ultrasonic pretreatment unit at a feed rate of 1 m / min and a tension of 90 N. The size of the radiation surface for ultrasonic softening treatment is 40 mm × 25 mm. Ultrasonic vibration is started at a frequency of 20 kHz and an amplitude of 20 μm. The ultrasonic softening time is 2 s, and the ultrasonic contact stress is 0.08 GPa (5.33% of the yield strength, corresponding to an elastic strain of 0.053%). This locally softens the amorphous alloy strip. S2. Blanking process: S2.1 Precise transmission: The amorphous alloy strip that has undergone ultrasonic softening treatment in step S1 is continuously transported to the blanking unit through a conveying device. The size of the blanking workpiece is 35 mm × 20 mm. The conveying step distance of the conveying device is equal to the distance between the center of the ultrasonic softening area and the center of the blanking area, so that the zirconium-based amorphous alloy strip is precisely moved from the ultrasonic pretreatment area to the blanking area, and the corresponding deviation between the center of the ultrasonic softening area and the center of the blanking area is controlled to be ≤0.1 mm. S2.2 Continuous punching: When the zirconium-based amorphous alloy strip reaches the punching position, punching is started with a punching force of 10 kN and a punching speed of 0.5 mm / s. After a single punching is completed, the conveying device continues to transport the zirconium-based amorphous alloy strip to the next "ultrasonic softening treatment-punching treatment" cycle, so as to realize the continuous processing of zirconium-based amorphous alloy strip.

[0057] The blanking force used in this embodiment is 10 kN, while the blanking force for conventional cold blanking of the same zirconium-based amorphous alloy strip is 18 kN. The blanking force used in this embodiment is only 55.6% of that of conventional cold blanking. Testing showed that both samples before and after ultrasonication were amorphous, with no significant change in surface quality. After ultrasonication, the material modulus and hardness decreased, the wear rate of the blanking die was 0.028 mm / 10,000 cycles, a decrease of approximately 58% compared to blanking without ultrasonication, the blanking force decreased by approximately 44.4%, and the product qualification rate was 95.5%.

[0058] Example 3 This embodiment provides an ultrasonic-assisted continuous punching forming method for copper-based amorphous alloy strips, including the following steps: S1. Ultrasonic softening treatment: S1.1 Preparation of the strip: Select a copper-based amorphous alloy strip with a width of 120 mm and a thickness of 0.12 mm as the raw material. The composition of the copper-based amorphous alloy strip is Cu. 50 Zr 42 The Al8 copper-based amorphous alloy strip has a yield strength of 1.7 GPa, an elastic strain limit of 2.1%, and a tensile strength of 1600 MPa. S1.2 Softening Treatment: The copper-based amorphous alloy strip is continuously fed to the ultrasonic pretreatment unit at a feed rate of 1.5 m / min and a tension of 100 N. The size of the radiation surface for ultrasonic softening treatment is 60 mm × 35 mm. Ultrasonic vibration is started at a frequency of 35 kHz and an amplitude of 40 μm. The ultrasonic softening time is 1 s, and the ultrasonic contact stress is 0.15 GPa (8.82% of the yield strength, corresponding to an elastic strain of 0.088%). This locally softens the amorphous alloy strip. S2, Blanking process: S2.1 Precise transmission: The copper-based amorphous alloy strip that has undergone ultrasonic softening treatment in step S1 is continuously transported to the blanking unit through a conveying device. The size of the blanking workpiece is 55 mm × 30 mm. The conveying step distance of the conveying device is equal to the distance between the center of the ultrasonic softening area and the center of the blanking area, so that the copper-based amorphous alloy strip is precisely moved from the ultrasonic pretreatment area to the blanking area, and the corresponding deviation between the center of the ultrasonic softening area and the center of the blanking area is controlled to be ≤0.1 mm. S2.2 Continuous punching: When the copper-based amorphous alloy strip reaches the punching position, punching is started with a punching force of 25 kN and a punching speed of 0.5 mm / s. After a single punching is completed, the conveying device continues to transport the copper-based amorphous alloy strip to the next "ultrasonic softening treatment-punching treatment" cycle, so as to realize the continuous processing of the copper-based amorphous alloy strip.

[0059] The blanking force used in this embodiment is 25 kN, while the blanking force for conventional cold blanking of the same copper-based amorphous alloy strip is 46 kN. The blanking force used in this embodiment is only 54.4% of that of conventional cold blanking. Testing showed that both the samples before and after ultrasonication were amorphous, with no significant change in surface quality. After ultrasonication, the material modulus and hardness decreased, the wear rate of the blanking die was 0.03 mm / 10,000 cycles, a decrease of approximately 58% compared to blanking without ultrasonication, the blanking force decreased by approximately 45.7%, and the product qualification rate was 97%.

[0060] Example 4 This embodiment provides an ultrasonic-assisted continuous punching forming method for iron-cobalt based amorphous alloy strips, including the following steps: S1. Ultrasonic softening treatment: S1.1, Strip Preparation: Select an iron-cobalt based amorphous alloy strip with a width of 90 mm and a thickness of 0.06 mm as the raw material. The composition of the iron-cobalt based amorphous alloy strip is (Fe... 0.94 Co 0.06 ) 78 Si 10 B 12 The iron-cobalt based amorphous alloy strip has a yield strength of 1.4 GPa, an elastic strain limit of 1.7%, and a tensile strength of 1300 MPa. S1.2 Softening Treatment: The iron-cobalt based amorphous alloy strip is continuously fed to the ultrasonic pretreatment unit at a feed rate of 0.8 m / min and a tension of 70 N. The size of the radiation surface for ultrasonic softening treatment is 45 mm × 28 mm. Ultrasonic vibration is started at a frequency of 15 kHz and an amplitude of 15 μm. The ultrasonic softening time is 3 s, and the ultrasonic contact stress is 0.06 GPa (4.29% of the yield strength, corresponding to an elastic strain of 0.043%). This locally softens the amorphous alloy strip. S2. Blanking process: S2.1 Precise transmission: The iron-cobalt-based amorphous alloy strip that has undergone ultrasonic softening treatment in step S1 is continuously transported to the blanking unit through a conveying device. The size of the blanking workpiece is 40 mm × 23 mm. The conveying step distance of the conveying device is equal to the distance between the center of the ultrasonic softening area and the center of the blanking area, so that the iron-cobalt-based amorphous alloy strip is precisely moved from the ultrasonic softening area to the blanking area, and the corresponding deviation between the center of the ultrasonic softening area and the center of the blanking area is controlled to be ≤0.1 mm. S2.2 Continuous punching: When the iron-cobalt-based amorphous alloy strip reaches the punching position, punching is started. The punching process is carried out with a punching force of 8 kN and a punching speed of 0.5 mm / s. After a single punching is completed, the conveying device continues to transport the iron-cobalt-based amorphous alloy strip to the next "ultrasonic softening treatment-punching treatment" cycle, so as to realize the continuous processing of the iron-cobalt-based amorphous alloy strip.

[0061] The blanking force used in this embodiment is 8 kN, while the blanking force for conventional cold blanking of the same iron-cobalt-based amorphous alloy strip is 14 kN. The blanking force used in this embodiment is only 57.1% of that of conventional cold blanking. Testing showed that both samples before and after ultrasonication were amorphous, with no significant change in surface quality. After ultrasonication, the material modulus and hardness decreased, the wear rate of the blanking die was 0.026 mm / 10,000 cycles, a decrease of approximately 60% compared to blanking without ultrasonication, the blanking force decreased by approximately 42.9%, and the product qualification rate was 95%.

[0062] Example 5 This embodiment provides an ultrasonic-assisted continuous punching forming method for nickel-based amorphous alloy strips, including the following steps: S1. Ultrasonic softening treatment: S1.1 Preparation of Strip: Select a nickel-based amorphous alloy strip with a width of 100 mm and a thickness of 0.15 mm as the raw material. The composition of the nickel-based amorphous alloy strip is Ni. 78 Si 10 B 12 The yield strength of the nickel-based amorphous alloy strip is 1.8 GPa, the elastic strain limit is 2.2%, and the tensile strength is 1700 MPa. S1.2 Softening Treatment: The nickel-based amorphous alloy strip is continuously fed to the ultrasonic pretreatment unit at a feed rate of 2 m / min and a tension of 120 N. The size of the radiation surface for ultrasonic softening treatment is 55 mm × 32 mm. Ultrasonic vibration is started at a frequency of 40 kHz and an amplitude of 45 μm. The ultrasonic softening time is 0.8 s, and the ultrasonic contact stress is 0.2 GPa (11.11% of the yield strength, corresponding to an elastic strain of 0.111%). This locally softens the amorphous alloy strip. S2. Blanking process: S2.1 Precise transmission: The nickel-based amorphous alloy strip that has undergone ultrasonic softening treatment in step S1 is continuously transported to the blanking unit through a conveying device. The size of the blanking workpiece is 50 mm × 27 mm. The conveying step distance of the conveying device is equal to the distance between the center of the ultrasonic softening area and the center of the blanking area, so that the nickel-based amorphous alloy strip is precisely moved from the ultrasonic pretreatment area to the blanking area, and the corresponding deviation between the center of the ultrasonic softening area and the center of the blanking area is controlled to be ≤0.1 mm. S2.2 Continuous punching: When the nickel-based amorphous alloy strip reaches the punching position, punching is started with a punching force of 34 kN and a punching speed of 0.5 mm / s. After a single punching is completed, the conveying device continues to transport the nickel-based amorphous alloy strip to the next "ultrasonic softening treatment-punching treatment" cycle, so as to realize the continuous processing of the nickel-based amorphous alloy strip.

[0063] The blanking force used in this embodiment is 34 N, while the blanking force for conventional cold blanking of the same nickel-based amorphous alloy strip is 52 kN. The blanking force used in this embodiment is only 65.4% of that of conventional cold blanking. Testing showed that both the samples before and after ultrasonication were amorphous, with no significant change in surface quality. After ultrasonication, the material modulus and hardness decreased, the wear rate of the blanking die was 0.032 mm / 10,000 cycles, a decrease of approximately 52% compared to blanking without ultrasonication, the blanking force decreased by approximately 34.6%, and the product qualification rate was 96.5%.

[0064] Example 6 This embodiment provides an ultrasonic-assisted continuous punching forming method for iron-zirconium-based amorphous alloy strips, including the following steps: S1. Ultrasonic softening treatment: S1.1 Preparation of the strip: Select a 100 mm wide and 0.15 mm thick iron-zirconium based amorphous alloy strip as the raw material. The composition of the iron-zirconium based amorphous alloy strip is Fe. 76 Zr4B 20 The yield strength of the iron-zirconium based amorphous alloy strip is 1.3 GPa, the elastic strain limit is 1.6%, and the tensile strength is 1200 MPa. S1.2 Softening Treatment: The iron-zirconium-based amorphous alloy strip is continuously fed to the ultrasonic pretreatment unit at a feed rate of 0.6 m / min and a tension of 60 N. The size of the radiation surface for ultrasonic softening treatment is 35 mm × 22 mm. Ultrasonic vibration is started at a frequency of 10 kHz and an amplitude of 10 μm. The ultrasonic softening time is 4 s, and the ultrasonic contact stress is 0.05 GPa (3.85% of the yield strength, corresponding to an elastic strain of 0.038%). This locally softens the amorphous alloy strip. S2. Blanking process: S2.1 Precise transmission: The iron-zirconium-based amorphous alloy strip that has undergone ultrasonic softening treatment in step S1 is continuously transported to the blanking unit through a conveying device. The size of the blanking workpiece is 30 mm × 18 mm. The conveying step distance of the conveying device is equal to the distance between the center of the ultrasonic softening area and the center of the blanking area, so that the iron-zirconium-based amorphous alloy strip is precisely moved from the ultrasonic pretreatment area to the blanking area, and the corresponding deviation between the center of the ultrasonic softening area and the center of the blanking area is controlled to be ≤0.1 mm. S2.2 Continuous punching: When the iron-zirconium-based amorphous alloy strip reaches the punching position, punching is started with a punching force of 15 kN and a punching speed of 0.5 mm / s. After a single punching is completed, the conveying device continues to transport the iron-zirconium-based amorphous alloy strip to the next "ultrasonic softening treatment-punching treatment" cycle, so as to realize the continuous processing of the iron-zirconium-based amorphous alloy strip.

[0065] The blanking force used in this embodiment is 15 kN, while the conventional cold blanking force for the same iron-zirconium-based amorphous alloy strip is 25 kN. The blanking force used in this embodiment is only 60% of that of conventional cold blanking. Testing showed that both the samples before and after ultrasonication were amorphous, with no significant change in surface quality. After ultrasonication, the material modulus and hardness decreased, the wear rate of the blanking die was 0.024 mm / 10,000 cycles, a decrease of approximately 63% compared to blanking without ultrasonication, the blanking force decreased by approximately 40%, and the product qualification rate was 94.5%.

[0066] Example 7 This embodiment provides an ultrasonic-assisted continuous punching forming method for copper-zirconium-based amorphous alloy strips, including the following steps: S1. Ultrasonic softening treatment: S1.1 Preparation of the strip: A copper-zirconium-based amorphous alloy strip with a width of 130 mm and a thickness of 0.11 mm is selected as the raw material. The composition of the copper-zirconium-based amorphous alloy strip is Cu. 50 Zr 43 The Al7 copper-zirconium based amorphous alloy strip has a yield strength of 1.65 GPa, an elastic strain limit of 2%, and a tensile strength of 1550 MPa. S1.2 Softening Treatment: The copper-zirconium-based amorphous alloy strip is continuously fed to the ultrasonic pretreatment unit at a feed rate of 1.8 m / min and a tension of 100 N. The size of the radiation surface for ultrasonic softening treatment is 65 mm × 38 mm. Ultrasonic vibration is started at a frequency of 50 kHz and an amplitude of 35 μm. The ultrasonic softening time is 1.2 s, and the ultrasonic contact stress is 0.25 GPa (15.15% of the yield strength, corresponding to an elastic strain of 0.152%). This locally softens the amorphous alloy strip. S2. Blanking process: S2.1 Precise transmission: The copper-zirconium-based amorphous alloy strip that has undergone ultrasonic softening treatment in step S1 is continuously transported to the blanking unit through a conveying device. The size of the blanking workpiece is 60 mm × 33 mm. The conveying step distance of the conveying device is equal to the distance between the center of the ultrasonic softening area and the center of the blanking area, so that the copper-zirconium-based amorphous alloy strip is precisely moved from the ultrasonic softening area to the blanking area, and the corresponding deviation between the center of the ultrasonic softening area and the center of the blanking area is controlled to be ≤0.1 mm. S2.2 Continuous punching: When the copper-zirconium-based amorphous alloy strip reaches the punching position, punching is started with a punching force of 26 kN and a punching speed of 0.5 mm / s. After a single punching is completed, the conveying device continues to transport the copper-zirconium-based amorphous alloy strip to the next "ultrasonic softening treatment-punching treatment" cycle, so as to realize the continuous processing of the copper-zirconium-based amorphous alloy strip.

[0067] The blanking force used in this embodiment is 26 kN, while the blanking force for conventional cold blanking of the same copper-zirconium-based amorphous alloy strip is 42 kN. The blanking force used in this embodiment is only 61.9% of that of conventional cold blanking. Testing showed that both samples before and after ultrasonication were amorphous, with no significant change in surface quality. After ultrasonication, the material modulus and hardness decreased, the wear rate of the blanking die was 0.033 mm / 10,000 cycles, a decrease of approximately 51% compared to blanking without ultrasonication, the blanking force decreased by approximately 38.1%, and the product qualification rate was 96.2%.

[0068] Example 8 This embodiment provides an ultrasonic-assisted continuous punching forming method for iron-copper based amorphous alloy strips, including the following steps: S1. Ultrasonic softening treatment: S1.1, Strip Preparation: Select an iron-copper based amorphous alloy strip with a width of 100 mm and a thickness of 0.09 mm as the raw material. The composition of the iron-copper based amorphous alloy strip is (Fe... 0.8 Cu 0.2 ) 78 Zr2B 20 The yield strength of the iron-copper based amorphous alloy strip is 1.55 GPa, the elastic strain limit is 1.9%, and the tensile strength is 1450 MPa. S1.2 Softening Treatment: The iron-copper based amorphous alloy strip is continuously fed to the ultrasonic pretreatment unit at a feed rate of 1.3 m / min and a tension of 95 N. The size of the radiation surface for ultrasonic softening treatment is 52 mm × 31 mm. Ultrasonic vibration is started at a frequency of 30 kHz and an amplitude of 25 μm. The ultrasonic softening time is 1.2 s, and the ultrasonic contact stress is 0.12 GPa (7.74% of the yield strength, corresponding to an elastic strain of 0.077%). This locally softens the amorphous alloy strip. S2. Blanking process: S2.1 Precise transmission: The iron-copper based amorphous alloy strip that has undergone ultrasonic softening treatment in step S1 is continuously transported to the blanking unit through a conveying device. The size of the blanking workpiece is 47 mm × 26 mm. The conveying step distance of the conveying device is equal to the distance between the center of the ultrasonic softening area and the center of the blanking area, so that the iron-copper based amorphous alloy strip is precisely moved from the ultrasonic pretreatment area to the blanking area, and the corresponding deviation between the center of the ultrasonic softening area and the center of the blanking area is controlled to be ≤0.1 mm. S2.2 Continuous punching: When the iron-copper based amorphous alloy strip reaches the punching position, punching is started. The punching process is carried out with a punching force of 16 kN and a punching speed of 0.5 mm / s. After a single punching is completed, the conveying device continues to transport the iron-copper based amorphous alloy strip to the next "ultrasonic softening treatment-punching treatment" cycle, so as to realize the continuous processing of the iron-copper based amorphous alloy strip.

[0069] The blanking force used in this embodiment is 16 kN, while the blanking force for conventional cold blanking of the same iron-copper based amorphous alloy strip is 25 kN. The blanking force used in this embodiment is only 64% of that of conventional cold blanking. Testing showed that both the samples before and after ultrasonication were amorphous, with no significant change in surface quality. After ultrasonication, the material modulus and hardness decreased, the wear rate of the blanking die was 0.027 mm / 10,000 cycles, a decrease of approximately 59% compared to blanking without ultrasonication, the blanking force decreased by approximately 36%, and the product qualification rate was 95.8%.

[0070] Example 9 This embodiment provides an ultrasonic-assisted continuous punching forming method for iron-copper based amorphous alloy strips, including the following steps: S1. Ultrasonic softening treatment: S1.1, Strip Preparation: Select an iron-copper based amorphous alloy strip with a width of 100 mm and a thickness of 0.1 mm as the raw material. The composition of the iron-copper based amorphous alloy strip is Fe. 81 Si 3.5 B 13.5 The C2 iron-copper based amorphous alloy strip has a yield strength of 1.9 GPa, an elastic strain limit of 1.27%, and a tensile strength of 1950 MPa. S1.2 Softening Treatment: The iron-copper based amorphous alloy strip is continuously fed to the ultrasonic pretreatment unit at a feed rate of 1.3 m / min and a tension of 95 N. The size of the radiation surface for ultrasonic softening treatment is 52 mm × 31 mm. Ultrasonic vibration is started at a frequency of 30 kHz and an amplitude of 25 μm. The ultrasonic softening time is 1.2 s and the ultrasonic contact stress is 0.15 GPa, thereby locally softening the amorphous alloy strip. S2. Blanking process: S2.1 Precise transmission: The iron-copper based amorphous alloy strip that has undergone ultrasonic softening treatment in step S1 is continuously transported to the blanking unit through a conveying device. The size of the blanking workpiece is 45 mm × 25 mm. The conveying step distance of the conveying device is equal to the distance between the center of the ultrasonic softening area and the center of the blanking area, so that the iron-copper based amorphous alloy strip is precisely moved from the ultrasonic pretreatment area to the blanking area, and the corresponding deviation between the center of the ultrasonic softening area and the center of the blanking area is controlled to be ≤0.1 mm. S2.2 Continuous punching: When the iron-copper based amorphous alloy strip reaches the punching position, punching is started with a punching force of 25 kN and a punching speed of 0.5 mm / s. After a single punching is completed, the conveying device continues to transport the iron-copper based amorphous alloy strip to the next "ultrasonic softening treatment-punching treatment" cycle, so as to realize the continuous processing of the iron-copper based amorphous alloy strip.

[0071] The blanking force used in this embodiment is 25 kN, while the blanking force for conventional cold blanking of the same iron-copper based amorphous alloy strip is 36 kN. The blanking force used in this embodiment is only 69.44% of that of conventional cold blanking. Testing showed that both the samples before and after ultrasonication were amorphous, with no significant change in surface quality. After ultrasonication, the material modulus and hardness decreased, the wear rate of the blanking die was 0.030 mm / 10,000 cycles, a decrease of approximately 62.5% compared to blanking without ultrasonication, the blanking force decreased by approximately 30.56%, and the product qualification rate was 96%.

[0072] Example 10 This embodiment provides an ultrasonic-assisted continuous punching forming system for amorphous alloy strips, such as... Figure 7 As shown, the device includes a support frame 7 and a feeding device 1, an ultrasonic pretreatment unit 2, a conveying device 3, a punching processing unit 4, and an unloading mechanism 5 arranged sequentially along the conveying direction of the amorphous alloy strip 8. It also includes a control unit 6 that is electrically connected to the ultrasonic pretreatment unit 2, the conveying device 3, and the punching processing unit 4, respectively.

[0073] The support frame 7 is integrally welded from high-strength alloy steel, and its overall structure has high rigidity and vibration resistance, providing a stable installation benchmark and support carrier for the feeding device 1, conveying device 3, ultrasonic pretreatment unit 2, punching unit 4, control unit 6, and unloading mechanism 5. A vertically arranged partition plate 71 is fixed inside the support frame 7, which isolates the internal space of the support frame 7 into two independent functional areas: the front is the ultrasonic pretreatment area, where the ultrasonic pretreatment unit 2 is located, and the rear is the punching area, where the punching unit 4 is located. The partition plate 71 effectively avoids vibration interference and cross-contamination of debris between the two areas. A strip channel is opened in the middle of the partition plate 71 along the conveying direction of the amorphous alloy strip 8. The width of the strip channel is 0.5-2 mm larger than the maximum width of the amorphous alloy strip 8, which ensures the smooth passage of the amorphous alloy strip 8 and prevents metal debris generated during the punching process from entering the ultrasonic pretreatment area, thus ensuring the stability of ultrasonic pretreatment and the surface quality of the amorphous alloy strip 8.

[0074] The feeding device 1 is fixedly installed at the entrance side of the ultrasonic pretreatment zone at the front end of the support frame 7, providing initial tension control and path guidance for the continuous conveying of the amorphous alloy strip 8. It mainly includes a brake wheel 11 and an idler wheel 12. The brake wheel 11 adopts an adjustable mounting structure for coaxially fixing the amorphous alloy strip roll, and the feeding speed is precisely controlled by adjusting the output torque of the brake. The idler wheel 12 is correspondingly arranged on the discharge side of the brake wheel 11. Through flexible contact with the surface of the amorphous alloy strip 8, it adjusts and stabilizes the conveying tension of the amorphous alloy strip 8 in real time, preventing slack accumulation or excessive stretching deformation of the amorphous alloy strip 8, ensuring that the amorphous alloy strip 8 is smoothly and stably conveyed to the ultrasonic pretreatment zone along the preset path. The surface of the idler wheel 12 is covered with a 2-3 mm thick polyurethane elastic layer, which has sufficient elasticity to adapt to the slight undulations of the amorphous alloy strip 8 surface, and avoids scratching the surface of the amorphous alloy strip 8 through flexible contact, while increasing the friction with the amorphous alloy strip 8 to stabilize the tension. During operation, the idler wheel 12 adheres to the surface of the amorphous alloy strip 8 under its own gravity, sensing the tension changes of the amorphous alloy strip 8 in real time during the conveying process. When the amorphous alloy strip 8 shows a tendency to slack off, the idler wheel 12 presses down on the amorphous alloy strip 8 under the action of gravity, and the torque adjustment of the brake wheel 11 increases the tension. When the tension of the amorphous alloy strip 8 is too high, the brake wheel 11 appropriately reduces the output torque, and the idler wheel 12 floats slightly with the strip, realizing real-time adjustment and stable control of tension. This effectively avoids the strip from slack accumulation, excessive stretching deformation, or conveying deviation, ensuring that the amorphous alloy strip 8 is smoothly and steadily conveyed to the ultrasonic pretreatment area along the preset path, providing a guarantee for the accurate positioning and uniform softening of the subsequent ultrasonic pretreatment.

[0075] The ultrasonic pretreatment unit 2, as the core component for softening the amorphous alloy strip 8, mainly consists of an ultrasonic component 21, a lifting mechanism 22, and a first sensor 23. The ultrasonic component 21 mainly includes an ultrasonic pressure head 211, an ultrasonic transducer 212, and an ultrasonic generator 213, which are used to apply stable ultrasonic vibrations to the amorphous alloy strip 8 to achieve local softening. The ultrasonic pressure head 211 is arranged directly above the ultrasonic softening area, and its radiation surface (the surface in contact with the strip) is a rectangular plane. The dimensions of this radiation surface in the width and length directions of the amorphous alloy strip 8 are both larger than the maximum external dimensions of the punched workpiece in the corresponding directions, and can completely cover the strip pretreatment area corresponding to the punched workpiece. The vibration output end of the ultrasonic transducer 212 is rigidly connected to the ultrasonic pressure head 211 to ensure lossless transmission of ultrasonic vibration energy. The ultrasonic generator 213 is located in the electrical control cabinet 9 on the side of the support frame 7, away from the ultrasonic pretreatment area and the punching area, to avoid vibration and debris interfering with its stable operation. The ultrasonic generator 213 is electrically connected to the ultrasonic transducer 212 via a high-frequency shielded cable, and simultaneously establishes a bidirectional signal connection with the control unit 6. It can receive frequency and power adjustment commands from the control unit 6, converting electrical energy into ultrasonic vibration energy of the corresponding frequency and outputting it to the ultrasonic transducer 212. It can also provide real-time feedback of its own operating status, facilitating closed-loop control by the control unit 6. The lifting mechanism 22 adopts a high-precision electric lead screw structure. Its upper end is fixed to the top crossbeam of the support frame 7 at the top of the ultrasonic pretreatment area via a mounting base. Its power output end is fixedly connected to the ultrasonic transducer 212 in the ultrasonic generator assembly, forming a series assembly structure of "support frame 7 - lifting mechanism 22 - ultrasonic transducer 212 - ultrasonic pressure head 211," used to drive the ultrasonic transducer 212 and ultrasonic pressure head 211 to move synchronously vertically. The first sensor 23 is a flexible optical tactile sensor, embedded in the pressure end of the ultrasonic indenter 211 (i.e., the radiating surface side in contact with the strip). The detection end face of the first sensor 23 is flush with the radiating surface, without protrusions or depressions, so as not to affect the transmission of ultrasonic vibration and to accurately detect contact stress. The first sensor 23 establishes an electrical connection with the control unit 6 through the internal channel of the ultrasonic indenter 211 and the ultrasonic transducer 212 via an internal signal cable, so as to achieve stable transmission of detection signals and avoid external cable entanglement or vibration interference. During operation, the first sensor 23 monitors the contact stress between the ultrasonic indenter 211 and the amorphous alloy strip 8 and the center position of the ultrasonic softening area in real time, and feeds back the detection signal to the control unit 6 in real time. The control unit 6 dynamically adjusts the lifting amount of the lifting mechanism 22 according to the feedback signal to stably control the contact stress within the range of 0.05-0.3 GPa, so as to avoid the strip from plastic deformation due to excessive stress and the ultrasonic energy transmission failure due to insufficient stress.

[0076] After the amorphous alloy strip 8 is conveyed to the preset position in the ultrasonic pretreatment area by the feeding device 1 and the conveying device 3, the control unit 6 instructs the lifting mechanism 22 to drive the ultrasonic pressure head 211 to descend until it contacts the surface of the amorphous alloy strip 8. The first sensor 23 detects the contact stress in real time and feeds back the signal. The lifting mechanism 22 finely adjusts the position according to the signal to stabilize the stress within the set range. Then, the control unit 6 starts the ultrasonic generator 213. The ultrasonic transducer 212 converts electrical energy into ultrasonic vibration energy and transmits it to the ultrasonic pressure head 211. Stable ultrasonic vibration is applied to the strip to be punched area through the radiation surface to complete local softening. After softening is completed, the lifting mechanism 22 drives the ultrasonic pressure head 211 to rise and reset. The conveying device 3 conveys the amorphous alloy strip 8 to the subsequent punching area to realize the continuous connection between pretreatment and punching.

[0077] The conveying device 3, as the core mechanism for the continuous transfer and precise positioning of the amorphous alloy strip 8, is arranged sequentially inside the support frame 7 along the conveying path of the amorphous alloy strip 8, connecting the feeding device 1, the ultrasonic pretreatment unit 2, and the blanking unit 4. Its core function is to smoothly, continuously, and accurately convey the amorphous alloy strip 8 output from the feeding device 1 to the ultrasonic pretreatment area for softening, and then transfer it to the blanking area. Simultaneously, it ensures precise alignment between the ultrasonic softening area of ​​the amorphous alloy strip 8 and the blanking area of ​​the blanking unit 4, providing positioning assurance for subsequent precision blanking. The conveying device 3 mainly consists of multiple sets of drive rollers 31, pressure rollers 32, and guide rollers 33.

[0078] To achieve stable conveying and positioning of the amorphous alloy strip 8 at different workstations, the conveying device 3 is equipped with three sets of active rollers 31 and pressure rollers 32, arranged in an upper and lower roller structure, and installed at three key workstations to form a complete continuous conveying link. The first set of rollers is located at the entrance of the ultrasonic pretreatment zone, adjacent to the discharge side of the feeding device 1, to receive the amorphous alloy strip 8 output by the feeding device 1 and accurately guide it into the ultrasonic pretreatment zone, while also helping to stabilize the initial conveying tension; the second set of rollers is located near the partition plate 71 between the ultrasonic pretreatment zone and the punching zone, on the discharge side of the strip channel, to smoothly transfer the ultrasonically softened amorphous alloy strip 8 to the punching zone, while also working with the guide structure to correct the posture of the amorphous alloy strip 8; the third set of rollers is installed at the exit of the punching zone, adjacent to the discharge side of the punching device, to pull the punched strip and waste material and convey it to the subsequent unloading mechanism 5, ensuring that the amorphous alloy strip 8 does not loosen or deviate during the punching process. All drive rollers 31 are driven by independent high-precision servo motors. The servo motors are connected to the control unit 6 in a two-way electrical manner. They can receive step distance and speed adjustment commands output by the control unit 6, and can also provide real-time feedback of the rotation speed and angle signals of the drive rollers 31, thereby realizing closed-loop control of the conveying status.

[0079] The guide roller 33, in conjunction with the active roller 31 and the pressure roller 32, stabilizes the conveying posture of the amorphous alloy strip 8. Two sets are configured, one between the first set of rollers and the separator plate 71, and the other between the second set of rollers and the exit of the punching area. The guide roller 33's shaft is horizontally arranged, and its axis is strictly parallel to the width direction of the amorphous alloy strip 8, ensuring that the amorphous alloy strip 8 is conveyed along a preset path. To avoid scratching the surface of the amorphous alloy strip 8 and to enhance the fit with the amorphous alloy strip 8 to correct its posture, the surface of the guide roller 33 is covered with a 3-5 mm thick layer of wear-resistant rubber. The rubber material is nitrile rubber, which has excellent wear resistance and elasticity. The guide roller 33 is mounted on the worktable 72 in the middle of the support frame 7 via an adjustable bearing seat 34. Its height can be finely adjusted vertically to accommodate amorphous alloy strips 8 of different thicknesses, ensuring a tight fit between the guide roller 33 and the surface of the amorphous alloy strip 8. This effectively suppresses lateral deviation and vertical warping during strip conveying, further stabilizing the conveying posture.

[0080] During operation, the amorphous alloy strip 8 is output by the feeding device 1 and then pulled into the ultrasonic pretreatment area by the first set of active rollers 31 and pressing rollers 32. The guide rollers 33 correct the conveying posture to ensure that the amorphous alloy strip 8 passes smoothly under the ultrasonic pressure head 211 to complete the softening. After softening, the second set of rollers pulls the amorphous alloy strip 8 through the strip channel of the partition plate 71. The guide rollers 33 correct the posture again and accurately convey the amorphous alloy strip 8 to the punching processing area. The control unit 6 combines the displacement signal fed back by the servo motor and the positioning signal of the second sensor 44 to finely adjust the speed of the active roller 31 to ensure that the softening area and the punching area are aligned. After punching, the third set of rollers pulls the amorphous alloy strip 8 and the waste to the unloading mechanism 5 to complete one conveying cycle and realize the continuous connection between ultrasonic pretreatment and punching processing.

[0081] The blanking processing unit 4 serves as the actuator for precision blanking of amorphous alloy strips 8. It is suitable for blanking processing of iron-based, zirconium-based, copper-based, nickel-based, iron-cobalt-based, iron-zirconium-based, copper-zirconium-based, and iron-copper-based amorphous alloy strips 8 with a thickness of 0.025-0.15 mm. Specifically, it includes a punch 41, a lower die 42, a blanking drive mechanism 43, and a second sensor 44.

[0082] The punch 41 is integrally machined from cemented carbide, possessing high hardness and excellent wear resistance, effectively resisting cutting wear during the amorphous alloy punching process and extending its service life. The punch 41 has a columnar structure, with a cutting edge at the lower end perfectly matching the shape of the workpiece. The cross-sectional dimensions of the punch 41 are designed according to the maximum shape of the workpiece, being 5-8 mm larger than the corresponding dimension of the workpiece to ensure uniform force distribution during punching. During assembly, the punch 41 is precisely positioned directly above the punching area, with its central axis coinciding with the geometric center of the punching area, ensuring that the punching force acts perpendicularly on the surface of the amorphous alloy strip 8, preventing workpiece deformation or die damage due to uneven loading. The top of the punch 41 has a positioning groove and a bolt through hole for rigid connection with the power output end of the punching drive mechanism 43.

[0083] The lower mold 42 is made of Cr 12 MoV die steel is made through quenching treatment, achieving a hardness of HRC60-62, combining high hardness with impact toughness, and can withstand the instantaneous impact force during the punching process. The lower die 42 is a plate-like structure, horizontally placed and fixed to the worktable 72 in the middle of the support frame 7 by positioning pins and fastening bolts, providing a stable support reference for the amorphous alloy strip 8. The lower die 42 has a die cavity and a material discharge hole in the middle that are adapted to the cutting edge of the punch 41. The die cavity size is 0.03-0.05 mm larger than the workpiece to be processed, and the diameter of the material discharge hole is 2-3 mm larger than the die cavity size, ensuring that the punched workpiece can be smoothly removed and separated from the scrap, avoiding material jamming that affects continuous production. The lower die 42 and the punch 41 are arranged symmetrically, with the geometric center of its die cavity completely coinciding with the central axis of the punch 41 and the center of the punching area, forming a precise punching fit pair, achieving efficient shearing and separation of the amorphous alloy strip 8.

[0084] The blanking drive mechanism 43 adopts a servo hydraulic cylinder, which has the advantages of precise and controllable stroke, stable power output, and fast response speed. It can precisely adjust the blanking speed, stroke, and blanking force of the punch 41 to adapt to the continuous blanking rhythm of the amorphous alloy strip 8. During assembly, the blanking drive mechanism 43 is vertically set directly above the punch 41. Its upper end is rigidly connected to the top crossbeam of the support frame 7 through a flange seat. The connection surface between the flange seat and the top of the support frame 7 is sealed to prevent blanking debris from entering the mechanism and affecting its operation. The power output end of the blanking drive mechanism 43 is engaged with the positioning groove on the top of the punch 41 through a positioning pin and then tightened with high-strength bolts to ensure lossless power transmission, so that the lifting and lowering movement of the punch 41 is completely synchronized with the extension and retraction movement of the blanking drive mechanism 43.

[0085] The second sensor 44 is a non-contact laser displacement sensor, which can accurately capture the center position of the punching area without contacting the strip, avoiding damage to the strip surface, and adapting to the high-speed inspection requirements of continuous production. The detection range of the second sensor 44 covers the punching area and its surrounding ±5 mm range, and can simultaneously identify the position information of the strip edge and the center of the punching area, realizing dual positioning calibration. During assembly, the second sensor 44 is set below the punching area and is installed at the lower end of the lower die 42 through an adjustable bracket. The bracket can be finely adjusted in the vertical and horizontal directions so that the sensor detection end faces upward and the detection center and the geometric center of the punching area are in the same vertical plane. The signal output end of the second sensor 44 is electrically connected to the control system through a shielded cable, and the power supply end is connected to the control unit 6, which can transmit the real-time detected center position signal of the punching area to the control unit 6. When the strip position shift causes the alignment deviation between the ultrasonically softened area and the punching area to exceed ±0.1 mm, the control unit 6 can instruct the transmission device 3 to finely adjust the position of the amorphous alloy strip 8 to ensure punching accuracy.

[0086] After ultrasonic pretreatment, the amorphous alloy strip 8 is conveyed to the punching area by the conveying device 3. The second sensor 44 detects the center position of the punching area and the position of the amorphous alloy strip 8 in real time and feeds the signal back to the control unit 6. After calibration, the control unit 6 instructs the punching drive mechanism 43 to start, driving the punch 41 to move vertically downward, and cooperate with the lower die 42 to form a shearing force to complete the punching of the amorphous alloy strip 8. After the punching is completed, the punching drive mechanism 43 drives the punch 41 to reset vertically upward, and the conveying device 3 conveys the amorphous alloy strip 8 and the waste to the unloading mechanism 5. The second sensor 44 continues to detect the center position of the area in the next punching cycle, waiting for the next punching instruction, to achieve continuous and precise punching.

[0087] The control unit 6, as the core control hub of the ultrasonic-assisted continuous punching forming system of amorphous alloy strip 8, is integrated in the electrical control cabinet 9 on the side of the support frame 7. It is connected to the feeding device 1, the conveying device 3, the ultrasonic pretreatment unit 2 and the punching processing unit 4 through shielded cables to achieve coordinated control of the entire process of ultrasonic pretreatment, strip conveying and punching forming. This ensures that the timing of each mechanism's actions is matched and the parameters are accurately controllable, thus guaranteeing the stability and accuracy of continuous processing of amorphous alloy strip 8.

[0088] The unloading mechanism 5 is located at the rear end of the support frame 7, adjacent to the punching area outlet of the punching processing unit 4. Its core function is to separate and collect the finished workpiece and the amorphous alloy strip waste after punching, avoiding material accumulation that could affect continuous production. It also ensures that the surface of the finished workpiece is not damaged and that the waste is collected in an orderly manner. The mechanism includes a take-up roller 51, an unloading plate 52, a receiving box 53, and a drive motor. The unloading plate 52 is made of stainless steel and is arranged at an angle. Its upper end is aligned with the material discharge hole of the lower die 42 of the punching device, and its lower end extends above the finished product receiving box 53. The surface is polished and covered with a thin polyurethane protective film to prevent scratches on the surface of the finished workpiece when it slips. The two ends of the take-up roller 51 are connected to the worktable 72 via bearing seats to reduce vibration and wear during the winding process and ensure winding stability. The drive motor is a speed-regulating servo motor, electrically connected to the control unit 6. It can receive speed adjustment commands from the control unit 6 and dynamically match the winding speed according to the front punching speed and scrap width to avoid excessive winding causing scrap to stretch and break, or excessive winding causing scrap to accumulate. The output shaft of the drive motor is connected to one end of the winding roller 51, driving the winding roller 51 to rotate smoothly and realize the orderly winding and collection of strip scrap.

[0089] During operation, the control unit 6 synchronously starts the drive motor of the unloading mechanism 5 based on the blanking completion signal from the blanking processing unit 4, driving the take-up roller 51 to rotate. The blanked strip waste is smoothly conveyed to the take-up roller 51 by the roller traction of the conveying device 3 at the exit of the blanking area. The anti-slip grooves on the surface of the take-up roller 51 achieve tight winding, completing the collection of waste. At the same time, the finished workpiece falls through the material leakage hole of the lower die 42 to the unloading plate 52, and slides along the unloading plate 52 into the collection box 53, realizing the synchronous separation and collection of finished products and waste. In addition, the speed of the drive motor is linked with the operating speed of the front-end conveying device 3 and the blanking processing unit 4, and is uniformly controlled by the control unit 6 to ensure that the unloading speed matches the overall production rhythm and ensures the continuous and stable operation of the device.

[0090] Performance testing: Figure 1The figure shows a comparison of X-ray diffraction (XRD) patterns of the amorphous alloy strips before and after ultrasonic punching in Example 1. The XRD patterns of the samples "before ultrasonic punching" and "after ultrasonic punching" are displayed. Both diffraction curves exhibit a broadened "bun"-shaped scattering peak within a scanning angle range of 20° to 80°, and the two peaks almost completely overlap, without any sharp Bragg diffraction peaks. This broadened scattering peak is a typical characteristic of amorphous materials (non-crystalline state), originating from the long-range disorder of the atomic arrangement within the material. The overlap of the two curves indicates that after ultrasonic pretreatment at a frequency of 28 kHz, an amplitude of 30 μm, a contact stress of 0.1 GPa, and a duration of 1.5 s, followed by punching with a punching force of approximately 150 N, the overall atomic structure of the material remains completely amorphous, and no crystallization phenomenon detectable by XRD has occurred. This indicates that the ultrasonic energy applied under elastic contact stress can only induce local, reversible rearrangement and micro-region viscous flow in amorphous alloy atomic clusters, thereby achieving "softening" of the material to reduce punching force, but it does not provide enough energy to induce long-term crystallization or phase transformation.

[0091] Figure 2 The images show a comparison of the surface morphology of the amorphous alloy strips before and after ultrasonic softening treatment in Example 1 using atomic force microscopy. Figure 2 Figure (a) shows the surface morphology of the amorphous alloy strip before ultrasonic punching using an atomic force microscope. Figure 2 Figure (b) shows the surface morphology of the amorphous alloy strip after ultrasonic punching using an atomic force microscope. Both surfaces exhibit "diffusely distributed micro-protrusions," corresponding to the short-range ordered atomic clusters of the amorphous alloy. However, the size and distribution density of the protrusions are more significant after ultrasonic punching, which is related to... Figure 1 The XRD results show that ultrasonic treatment induced local relaxation of the amorphous structure, leading to rearrangement of short-range ordered regions and enhanced surface morphology fluctuations. Although the surface was slightly rough after ultrasonic punching, the height fluctuations remained at the nanometer level, far below the thickness of the amorphous strip, indicating that ultrasonic punching did not cause severe surface damage and could still ensure the surface quality of the strip. The change in surface morphology is a microscopic manifestation of "amorphous structure relaxation," verifying that ultrasonic treatment does indeed act on the atomic-level structure of the amorphous strip and providing morphological evidence for "ultrasonic softening reducing punching force."

[0092] Figure 3 This is a comparison of the surface roughness of the amorphous alloy strip before and after ultrasonic punching in Example 1. Figure 3In the diagram, "before ultrasonication" refers to the strip before ultrasonic punching, and "after ultrasonication" refers to the strip after treatment. The surface roughness before ultrasonication is approximately 2.0 nm, and after ultrasonication, it is approximately 3.3 nm, showing a slight increase in surface roughness. Combining the previous AFM morphology images and XRD results, the increase in roughness is due to the relaxation of the short-range ordered structure (local atomic rearrangement) of the amorphous alloy caused by ultrasonic vibration. This increases the number and size of the originally smooth microscopic protrusions on the surface, leading to enhanced surface undulation and ultimately a slight increase in roughness. This slight change in roughness indicates that ultrasonic punching achieves the core objectives of "softening the strip and reducing punching force" without causing serious surface damage, thus ensuring the surface quality of the amorphous strip.

[0093] Figure 4 This is a comparison diagram of the mechanical properties of the amorphous alloy strips before and after ultrasonic pretreatment in Example 1. Figure 4 In this text, "before ultrasonic treatment" refers to the strip before ultrasonic punching, and "after ultrasonic treatment" refers to the strip after treatment. Before ultrasonic treatment, the modulus is approximately 125 GPa and the hardness is approximately 11 GPa. After ultrasonic treatment, the modulus decreases to approximately 110 GPa and the hardness decreases to approximately 9.5 GPa. Ultrasonic vibration causes local rearrangement of atoms in the amorphous alloy, reducing structural defects and simultaneously lowering the interatomic bonding strength. This directly manifests as a slight decrease in modulus (the material's resistance to elastic deformation) and hardness (the material's resistance to plastic deformation). Higher hardness and modulus in amorphous alloys require greater shearing force during punching, making the workpiece more prone to cracking. Ultrasonic pretreatment, by reducing these two mechanical properties, achieves the goal of "softening the strip," thereby reducing the difficulty of subsequent punching and the defect rate of the workpiece.

[0094] Figure 5 This is a comparison chart of the wear rate of the blanking die before and after the blanking process in Example 1. Figure 5 The wear rate is expressed in mm / 10,000 cycles, representing the wear amount of the die after 10,000 punching cycles. A lower wear rate indicates less die wear and a longer lifespan. In the figure, "non-ultrasonic punching" corresponds to the die wear situation of direct punching (without ultrasonic pretreatment), and "ultrasonic punching" corresponds to the die wear situation of punching after ultrasonic pretreatment. The die wear rate of non-ultrasonic punching is approximately 0.05 mm / 10,000 cycles, while the die wear rate of ultrasonic punching drops to approximately 0.025 mm / 10,000 cycles. Amorphous alloys without ultrasonic treatment have higher hardness and modulus, requiring greater shearing force during punching. This results in stronger friction and impact between the die and the strip, leading to faster die wear. Ultrasonic pretreatment reduces the hardness and modulus of the strip, significantly reducing the shearing force required for punching. The load and friction on the die are weakened, thus significantly reducing the wear rate. The die wear rate of ultrasonic punching is only half that of non-ultrasonic punching, meaning the die lifespan can be increased by approximately 100%, significantly reducing the cost of die replacement and maintenance.

[0095] Figure 6 This is a comparison diagram of the punching force before and after ultrasonic softening treatment in Example 1. Figure 6 The blanking force represents the shear force required during the blanking process; a smaller value indicates easier blanking. "Before ultrasonication" corresponds to direct blanking (without ultrasonic pretreatment), while "after ultrasonication" corresponds to blanking after ultrasonic pretreatment. The blanking force before ultrasonication is approximately 31.2 kN, and the blanking force after ultrasonication decreases to approximately 15 kN. Ultrasonic vibration reduces the modulus and hardness of amorphous alloys, weakens the interatomic bonding strength, and significantly reduces the plastic deformation resistance of the strip to be blanked. Therefore, only a smaller shear force is needed to complete material separation during blanking, resulting in a significant decrease in blanking force. This significant reduction in blanking force is a direct process indicator of "strip softening achieved through ultrasonic pretreatment," proving that this process effectively reduces the processing difficulty of amorphous alloys.

[0096] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention, and not to limit them; although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some or all of the technical features; and these modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the scope of the technical solutions of the embodiments of the present invention.

Claims

1. A method for ultrasonic-assisted continuous punching forming of amorphous alloy strips, characterized in that, Includes the following steps: S1. Ultrasonic softening treatment: The amorphous alloy strip is continuously conveyed to the ultrasonic pretreatment unit, ultrasonic waves are applied to the amorphous alloy strip to soften it, and the ultrasonic contact stress is controlled to be less than the yield strength of the amorphous alloy strip, so that the amorphous alloy strip on the ultrasonic softening treatment radiation surface is softened. S2. Blanking process: The amorphous alloy strip after ultrasonic softening in step S1 is continuously conveyed to the blanking process unit through a conveying device, so that the center of the ultrasonic softening area of ​​the amorphous alloy strip is aligned with the center of the blanking area of ​​the blanking process unit, and then continuous blanking is performed.

2. The ultrasonic-assisted continuous punching forming method for amorphous alloy strips according to claim 1, characterized in that, The composition of the amorphous alloy strip is selected from one of the following: iron-based amorphous alloy, zirconium-based amorphous alloy, copper-based amorphous alloy, nickel-based amorphous alloy, iron-cobalt-based amorphous alloy, iron-zirconium-based amorphous alloy, copper-zirconium-based amorphous alloy, and iron-copper-based amorphous alloy.

3. The ultrasonic-assisted continuous punching forming method for amorphous alloy strips according to claim 2, characterized in that, The concentration of Fe 80 Si9B 11 、Fe 78 If 10 B 12 、Fe 77.5 Si9B 12 Nb 1.5 、Zr 56 The 28 Al 10 Ni6、Zr 65 The 17.5 Al 10 Nor 7.5 、Zr 62 The 20 Al 10 Ag8、Cu 50 Zr 42 Al8、Cu 56 Zr 36 Al8、Cu 54 Zr 36 Al8Hf2、Ni 78 If 10 B 12 ,Nor 75 Cr5P 16 B4、Ni 60 Fe 20 P 14 B6、Ni 45 Co 25 Fe5P 18 B7、(Fe 0.94 Co 0.06 ) 78 If 10 B 12 、Fe 72 Co6Si 10 B 12 、Co 66 Fe4Ni2Si 10 B 16 、Co 71 Fe4MoSi 10 B 14 、(Fe 0.95 Zr 0.05 ) 80 B 20 、Fe 76 Zr4B 20 、(Fe 0.65 Zr 0.35 ) 96 B 24 、Cu 50 Zr 43 Al7、Cu 56 Zr 34 Ti 10 Cu 48 Zr 44 Al8Ag5, (Fe 0.8 Cu 0.2 ) 78 Zr2B 20 Fe 81 Si 3.5 B 13.5 C2, Fe 70 Cu 10 Zr5B 15 and (Fe 0.92 Cu 0.08 ) 79.5 Si 10 B9Nb 1.5 One of them.

4. The ultrasonic-assisted continuous punching forming method for amorphous alloy strips according to claim 1, characterized in that, The frequency of the ultrasound in step S1 is 10 kHz to 100 kHz, the amplitude is 10 to 50 μm, and the ultrasound softening time is 1 to 10 s.

5. The ultrasonic-assisted continuous punching forming method for amorphous alloy strips according to claim 1, characterized in that, In step S1, the ultrasonic contact stress is 0.05-0.3 GPa.

6. The ultrasonic-assisted continuous punching forming method for amorphous alloy strips according to claim 1, characterized in that, In step S2, the corresponding deviation between the center of the ultrasonic softening region and the center of the punching region is ≤0.1 mm, the length of the ultrasonic softening region is greater than the length of the punching region, and the width of the ultrasonic softening region is greater than the width of the punching region.

7. The ultrasonic-assisted continuous punching forming method for amorphous alloy strips according to claim 6, characterized in that, The length of the ultrasonic softening region is 2-20 mm longer than the length of the punching region, and the width of the ultrasonic softening region is 2-20 mm wider than the width of the punching region.

8. The ultrasonic-assisted continuous punching forming method for amorphous alloy strips according to claim 6, characterized in that, The conveying and positioning accuracy of the conveying device is ±0.01 mm.

9. An ultrasonic-assisted continuous punching forming system for amorphous alloy strips, characterized in that, include: The ultrasonic pretreatment unit (2) is used to apply ultrasonic waves to the amorphous alloy strip (8) for ultrasonic softening. A feeding device (1) is provided at the feed end of the ultrasonic pretreatment unit (2) for continuously feeding amorphous alloy strips (8) into the ultrasonic pretreatment unit (2); The punching unit (4) is set at the discharge end of the ultrasonic pretreatment unit (2) and is used to continuously punch the ultrasonically softened amorphous alloy strip (8). A conveying device (3) is provided on the conveying path of the amorphous alloy strip (8) for continuously and accurately conveying the amorphous alloy strip (8) from the ultrasonic pretreatment unit (2) to the punching unit (4) and aligning the ultrasonic softening area of ​​the amorphous alloy strip (8) with the punching area of ​​the punching unit (4). The control unit (6) is electrically connected to the ultrasonic pretreatment unit (2), the punching unit (4) and the conveying device (3) for coordinating control of the ultrasonic pretreatment, conveying and punching processes.

10. The ultrasonic-assisted continuous punching forming system for amorphous alloy strips according to claim 9, characterized in that, The ultrasonic pretreatment unit (2) and the blanking unit (4) are located in the same support frame (7). The support frame (7) is divided into an ultrasonic pretreatment area and a blanking area by a partition plate (71). The ultrasonic pretreatment unit (2) is located in the ultrasonic pretreatment area, and the blanking unit (4) is located in the blanking area. A strip channel is provided on the partition plate (71), and the amorphous alloy strip (8) can enter the blanking area from the ultrasonic pretreatment area through the strip channel.

11. The ultrasonic-assisted continuous punching forming system for amorphous alloy strips according to claim 10, characterized in that, The ultrasonic preprocessing unit (2) includes: An ultrasonic component (21) includes an ultrasonic indenter (211), an ultrasonic transducer (212), and an ultrasonic generator (213) for applying ultrasonic vibrations to the amorphous alloy strip (8); the ultrasonic indenter (211) is positioned above the area of ​​the amorphous alloy strip (8) to be ultrasonically softened; the vibration output end of the ultrasonic transducer (212) is rigidly connected to the ultrasonic indenter (211); and the ultrasonic generator (213) is electrically connected to the ultrasonic transducer (212). The lifting mechanism (22) is located directly above the ultrasonic pressure head (211) and the ultrasonic transducer (212) for driving the lifting movement of the ultrasonic pressure head (211) and the ultrasonic transducer (212), and its upper end is fixed on the support frame (7), and its lower end is rigidly connected to the ultrasonic transducer (212). The first sensor (23) is embedded in the pressure end of the ultrasonic indenter (211) and is used to detect the ultrasonic contact stress applied by the ultrasonic indenter (211) to the amorphous alloy strip (8) and the center position of the ultrasonic softening area. The ultrasonic generator (213), the lifting mechanism (22), and the first sensor (23) are also electrically connected to the control unit (6).

12. The ultrasonic-assisted continuous punching forming system for amorphous alloy strips according to claim 10, characterized in that, The blanking processing unit (4) includes: A punch (41) is positioned directly above the punching area for performing punching processing on the amorphous alloy strip (8); The lower die (42) is located directly below the punching area and is installed on the worktable (72) in the middle of the support frame (7). It works with the punch (41) to punch the amorphous alloy strip (8). The punching drive mechanism (43) is located above the punch (41), with its upper end fixed to the top of the support frame (7), and its power output end is rigidly connected to the punch (41) to drive the punch (41) to move up and down. The second sensor (44) is located below the blanking area and installed at the lower end of the lower die (42) to detect the center position of the blanking area. The punching drive mechanism (43) and the second sensor (44) are electrically connected to the control unit (6).

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