Ultrasonic vibration composite intelligent cutter handle for low-voltage micro-arc discharge machining

Abstract

According to the ultrasonic vibration composite intelligent cutter handle for low-voltage micro-arc discharge machining, high-frequency micro-impact and cavitation effects generated by ultrasonic vibration are used for cooperatively regulating and controlling interpolar medium circulation, electric corrosion product migration and thermal field distribution in the low-voltage micro-arc discharge process, the discharge stability and the material removal efficiency are remarkably improved, and the machining precision is improved. And meanwhile, the formation of a heat affected zone and a recast layer is inhibited, so that the unification of high efficiency and high precision is realized. The sensor assembly integrated in the cutter handle can monitor the machining cutting force in real time, data support is provided for process optimization and cutter state early warning, and the process controllability is enhanced. And an integral circular ring type non-contact wireless power supply mode is adopted, so that cable winding and abrasion are avoided, and the reliability, safety and power transmission efficiency of the system are improved. The center water outlet hole designed in the cutter handle not only provides a cooling and chip removal channel for electrical discharge machining, but also synchronously cools an ultrasonic vibration system and a sensor which are integrated in the center water outlet hole, and the service life of key components is prolonged.

Description

Technical Field

[0001] This invention relates to the field of low-voltage micro-arc discharge machining technology, and in particular to an ultrasonic vibration composite smart tool holder for low-voltage micro-arc discharge machining. Background Technology

[0002] With the ever-increasing performance requirements of cutting-edge technology products in fields such as information, control, artificial intelligence, and military, the demand for machining difficult-to-machine materials, such as nickel-based superalloys, titanium alloys, and silicon carbide ceramic matrix composites, requiring high precision, high speed, high temperature resistance, and corrosion resistance, is becoming increasingly urgent. Traditional machining methods generally suffer from severe tool wear, low machining efficiency, and high costs when dealing with such materials, making it difficult to meet the requirements of modern precision manufacturing.

[0003] Low-voltage micro-arc discharge machining (LAD) is a novel special electrical discharge machining method developed from short-arc machining. It achieves efficient, non-contact removal of conductive materials by forming a plasma micro-arc discharge under low voltage and high current conditions. Compared to the higher operating voltage of traditional short-arc machining (typically above 15V), LAD significantly reduces the operating voltage to approximately 3-30V, enabling precise control of discharge energy. This reduces single-discharge energy and macroscopic heat input while achieving efficient material removal, making it possible to obtain higher machining accuracy and better surface quality. On the other hand, ultrasonic vibration technology, through high-frequency micro-impact and cavitation effects on the tool end face, can effectively improve the machining interface state, promote chip removal, inhibit recast layer formation, and disturb the interelectrode medium during EDM, improving discharge uniformity and stability. Therefore, combining ultrasonic vibration with LAD is considered an effective way to improve the machining quality and efficiency of difficult-to-machine materials.

[0004] However, existing low-voltage micro-arc discharge machining (DAM) technologies still face challenges when applied to complex structures and difficult-to-machine materials, including unstable discharge gaps, poor removal of electro-erosion products, and significant heat accumulation in the machining area. In particular, effective and integrated methods are lacking in process monitoring and adaptive control of process parameters. Currently, research combining ultrasonic vibration units with DAM systems often employs external, separate structures, where the vibration device is independent of the machining spindle. This structure results in long energy transfer paths, high losses, low system integration, and sluggish dynamic response, making it difficult to achieve real-time coordinated matching and control of vibration parameters and discharge energy. Meanwhile, the research and application of intelligent toolholder structures with state-aware capabilities in DAM are still in their early stages. Existing toolholders cannot integrate multi-functional modules such as vibration, sensing, and wireless power supply within a compact space, failing to meet the demands of multi-field collaborative machining for precise dynamic control of the interface and real-time process monitoring. Therefore, developing an integrated intelligent toolholder with a compact structure, high integration, effective coupling of ultrasonic vibration and low-voltage micro-arc discharge, and online monitoring capabilities has become a pressing technical problem in this field. Summary of the Invention

[0005] The purpose of this invention is to provide an ultrasonic vibration composite smart tool holder for low-pressure micro-arc discharge machining, so as to solve the problems existing in the prior art.

[0006] To achieve the above objectives, the present invention provides the following solution: This invention provides an ultrasonic vibration composite intelligent tool holder for low-voltage micro-arc discharge machining, applied to a detachably connected machine tool spindle, comprising: The tool holder body is used to connect to the machine tool spindle via a tool holder collet; An ultrasonic vibration device is arranged around the tool holder body to provide high-frequency vibration during the machining process; A sensor integration component is disposed on the tool holder body for monitoring the cutting force during the machining process and transmitting information. A low-voltage micro-arc ultrasonic wireless power supply device is arranged around the tool holder chuck and opposite to the ultrasonic vibration device, and is used to provide power to the ultrasonic vibration device wirelessly.

[0007] Preferably, the knife handle body comprises: A tapered shank for connecting to the tool holder collet; A flange is located below the taper shank of the tool holder and is connected to the sensor integration assembly; A fixed end cap is used to fix the ultrasonic vibration device; A clamp is connected to the end of the ultrasonic vibration device; The tool electrode is detachably connected to the chuck.

[0008] Preferably, the tool holder body has a central water outlet hole inside, which is used to deliver coolant and achieve cooling and chip removal.

[0009] Preferably, the outer cover of the knife handle body is provided with a protective cover, the protective cover has screw holes, and is fixedly connected to the knife handle taper and sensor integrated assembly by connecting bolts to achieve insulation and sealing.

[0010] Preferably, the ultrasonic vibration device comprises: Insulating gaskets; Piezoelectric ceramics are disposed between the insulating pads; An amplitude transformer is connected to the front end of the piezoelectric ceramic. A fixed end cap is used to fix the ultrasonic vibration device to the handle body.

[0011] Preferably, there are multiple piezoelectric ceramics, which are evenly arranged circumferentially; the insulating gasket, piezoelectric ceramics and amplitude transformer are all provided with through holes that communicate with the central water outlet.

[0012] Preferably, the sensor integration component includes: Force sensor; A circuit board is electrically connected to the force sensor, and the circuit board integrates a signal acquisition module, a data processing module, and a wireless transmission module. A toroidal lithium battery powers the circuit board and the force sensor.

[0013] Preferably, the circuit board is provided with a charging port for charging the toroidal lithium battery; the wireless transmission module is a WiFi module for transmitting processing status information to external devices in real time.

[0014] Preferably, the low-pressure micro-arc ultrasonic wireless power-on device is fixed to the end of the tool holder chuck by connecting bolts, and a gap of 3-5mm is provided between the low-pressure micro-arc ultrasonic wireless power-on device and the tool holder body.

[0015] Preferably, the low-voltage micro-arc ultrasonic wireless power-on device includes a retainer, a positioning extension frame, and a wireless transmitter. The wireless transmitter has a built-in power supply unit for supplying power to the ultrasonic vibration device in a non-contact manner.

[0016] The present invention achieves the following beneficial technical effects compared to the prior art: This invention provides an ultrasonic vibration composite intelligent tool holder for low-voltage micro-arc discharge machining. It innovatively integrates an ultrasonic vibration device, a sensor integration component, and a low-voltage micro-arc ultrasonic wireless power-on device onto the tool holder body, forming an integrated and compact composite machining execution unit. This tool holder utilizes the high-frequency micro-impact and cavitation effect generated by ultrasonic vibration to synergistically regulate the interelectrode medium circulation, electro-erosion product migration, and thermal field distribution during the low-voltage micro-arc discharge process, significantly improving discharge stability and material removal efficiency while suppressing the formation of the heat-affected zone and recast layer, thus achieving a balance between high efficiency and high precision. The sensor component integrated inside the tool holder can monitor the machining cutting force in real time, providing data support for process optimization and tool status early warning, enhancing process controllability. The use of an integral circular non-contact wireless power supply method avoids cable tangling and wear, improving system reliability, safety, and power transmission efficiency. The central water outlet designed inside the tool holder not only provides cooling and chip removal channels for discharge machining but also simultaneously cools the integrated ultrasonic vibration system and sensors, extending the service life of key components. Furthermore, the overall insulation design effectively isolates the discharge circuit, protecting internal electronic components. In summary, this intelligent tool holder features a compact structure and high functional integration, effectively solving problems such as high energy consumption, slow response, and lack of real-time monitoring in traditional split-type composite machining systems. It provides a reliable equipment foundation for high-quality and high-efficiency composite machining of difficult-to-machine materials. Attached Figure Description

[0017] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the embodiments will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0018] Figure 1 A schematic diagram of the ultrasonic vibration composite smart tool holder for low-voltage micro-arc discharge machining provided by the present invention; Figure 2 An exploded structural diagram of the ultrasonic vibration composite smart tool holder for low-pressure micro-arc discharge machining provided by the present invention. Figure 3 for Figure 1 Schematic diagram of a medium-low voltage micro-arc ultrasonic wireless power-on device; Figure 4 A schematic cross-sectional view of the ultrasonic vibration composite smart tool holder for low-voltage micro-arc discharge machining provided by the present invention. Figure 5 for Figure 2 Schematic diagram of a sensor integration component system; The annotations in the attached figures are explained as follows: In the diagram: 10. Tool holder chuck; 20. Tool holder body; 30. Low-voltage micro-arc ultrasonic wireless power-on device; 40. Ultrasonic vibration device; 50. Sensor integrated assembly; 60. Protective cover; 70. Connecting bolt; 21. Tool holder taper shank; 22. Fixed end cap; 23. Chuck; 24. Nut; 25. Tool electrode; 31. Connecting bolt; 32. Cage; 33. Positioning extension frame; 34. Wireless transmitter; 41. Positioning nut; 42. Piezoelectric ceramic; 43. Insulating gasket; 44. Ultrasonic amplitude transformer; 51. Circuit board; 52. Ring-shaped lithium battery; 53. Force sensor; 101. Internal locking thread; 102. Center water outlet; 103. Electrode inner hole; 401. Inner sleeve; 501. Cable groove; 511. Charging port; 512. Signal acquisition module; 513. Data processing module; 514. WiFi transmission module. Detailed Implementation

[0019] Unless otherwise specified, the terms "connection" and "linkage" used in this application include both direct and indirect connections (linkages). In the description of this invention, it should be understood that the terms "upper," "lower," "front," "rear," "left," "right," "vertical," "horizontal," "top," "bottom," "inner," "outer," "clockwise," and "counterclockwise," etc., indicating orientations or positional relationships based on the orientations or positional relationships shown in the accompanying drawings, are used only for the convenience of describing the invention and for simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on the invention.

[0020] In this invention, unless otherwise explicitly specified and limited, "above" or "below" the second feature can mean that the first feature is in direct contact with the second feature, or that the first feature is in indirect contact with the second feature through an intermediate medium. Furthermore, "above," "over," and "on top" of the second feature can mean that the first feature is directly above or diagonally above the second feature, or simply that the first feature is at a higher horizontal level than the second feature. "Below," "below," and "under" the second feature can mean that the first feature is directly below or diagonally below the second feature, or simply that the first feature is at a lower horizontal level than the second feature.

[0021] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0022] The purpose of this invention is to provide an ultrasonic vibration composite smart tool holder for low-pressure micro-arc discharge machining, so as to solve the problems existing in the prior art.

[0023] To make the above-mentioned objects, features and advantages of the present invention more apparent and understandable, the present invention will be further described in detail below with reference to the accompanying drawings and specific embodiments.

[0024] Example 1: Please see Figures 1 to 4 This invention provides an ultrasonic vibration composite smart tool holder for low-voltage micro-arc discharge machining. The tool holder is detachably connected to a machine tool spindle (not shown) and fixed via a tool holder chuck 10. The smart tool holder mainly includes a tool holder body 20, an ultrasonic vibration device 40 and a sensor integration assembly 50 integrated on the tool holder body 20, and a low-voltage micro-arc ultrasonic wireless power-on device 30 arranged around the tool holder chuck 10.

[0025] Specifically, the tool holder body 20 constitutes the core support structure of the intelligent tool holder. Its front end features a tool holder taper shank 21, which precisely engages with the tool holder chuck 10 of the machine tool spindle to transmit torque and rotational motion. A flange (not shown separately in the figure) is connected axially below the tool holder taper shank 21. This flange is securely connected to the sensor integration assembly 50, ensuring the structural stability of the sensing module and the reliability of signal transmission under high-speed rotation. A central water outlet 102 is axially distributed throughout the interior of the tool holder body 20. This channel not only delivers coolant (such as deionized water or special working fluid) during low-pressure micro-arc machining to cool the machining area, tool electrode, and key internal components of the tool holder, but also utilizes the pressure boosting effect generated by the small orifice to promote the discharge of electro-erosion products in the machining gap and assist in arc interruption, preventing the accumulation of molten material. An ultrasonic vibration device 40 is mounted on the front end of the tool holder body 20 via a fixed end cap 22, and a chuck 23 is connected to its end. The tool electrode 25 is detachably fastened to the chuck 23 via a nut 24, ensuring the installation accuracy and conductivity reliability of the tool electrode 25. To protect the internal precision components and achieve full-path insulation, a protective cover 60 is provided on the outer surface of the tool holder body 20. The protective cover 60 has screw holes and is fastened to the housing of the tool holder taper shank 21 and the sensor integration assembly 50 via connecting bolts 70, forming a sealed protective environment that effectively isolates external dust, coolant, and stray currents that may be generated during electrical discharge machining.

[0026] Furthermore, the ultrasonic vibration device 40 is the core component for generating high-frequency mechanical vibration, and it is arranged in a ring inside the knife handle body 20. This device mainly includes insulating gaskets 43 stacked axially, piezoelectric ceramics 42, and an ultrasonic amplitude transformer 44 connected to the front end. In a preferred embodiment, four piezoelectric ceramics 42 are used, sandwiched between two insulating gaskets 43. The front insulating gasket 43 is tightly fitted to the fixed end cap 22, while the rear insulating gasket 43 is pressed by a positioning nut 41, thereby firmly fixing the entire piezoelectric transducer assembly inside the knife handle body 20. Both the insulating gaskets 43 and the piezoelectric ceramics 42 have through holes, ensuring that the central water outlet 102 inside remains open, allowing coolant to flow smoothly and cool the piezoelectric ceramics 42. The ultrasonic amplitude transformer 44 is connected to the front end of the piezoelectric ceramic stack. Its function is to mechanically amplify the small amplitude generated by the piezoelectric ceramic and efficiently transmit the amplified ultrasonic frequency vibration to the chuck 23 and tool electrode 25 at the front end, driving the tool electrode 25 to vibrate at high frequency along the axial direction (i.e., parallel to the machine tool spindle).

[0027] Furthermore, the sensor integration component 50 is responsible for real-time status sensing and information processing of the processing process. Please refer to... Figure 4 and Figure 5 The component mainly includes a force sensor 53, a circuit board 51, and a toroidal lithium battery 52. ​​The force sensor 53 (such as a strain gauge sensor) is positioned appropriately inside the tool holder body 20 to sense changes in cutting force on the tool during machining in real time. The circuit board 51 is electrically connected to the force sensor 53 and the toroidal lithium battery 52 via wires in a wire slot 501. The circuit board 51 integrates a charging port 511, a signal acquisition module 512, a data processing module 513, and a WiFi transmission module 514. The toroidal lithium battery 52 provides power to the entire sensing and processing circuit, and the charging port 511 can be used for wireless or wired charging. During operation, the force sensor 53 transmits the acquired analog strain force signal to the signal acquisition module 512 for amplification and conditioning. The data processing module 513 then converts it into a digital signal, which is finally wirelessly transmitted to an external computer or control system via the WiFi transmission module 514, enabling online monitoring of the machining force state, tool wear warning, and optimization of process parameters.

[0028] Furthermore, the low-voltage micro-arc ultrasonic wireless power-on device 30 is key to achieving non-contact energy transmission. For example... Figure 1 and Figure 3As shown, the device is fixedly mounted on the end of the tool holder chuck 10 by connecting bolts 31. It mainly consists of a retainer 32, a positioning extension bracket 33, and a wireless transmitter 34. The wireless transmitter 34 integrates a power supply coil and other units, used to wirelessly transmit electrical energy provided by an external ultrasonic generator to the ultrasonic vibration device 40 inside the tool holder via electromagnetic induction (its receiving coil can be integrated near the piezoelectric ceramic assembly). During installation, it is necessary to ensure a radial gap of approximately 3-5 mm between the wireless transmitter 34 and the tool holder body 20 (especially its external protective cover 60). This avoids physical interference between the rotating tool holder body 20 and the stationary wireless power supply device 30, ensuring smooth and safe spindle rotation; furthermore, this gap size is optimized to achieve high wireless energy transmission efficiency while ensuring sufficient insulation safety distance.

[0029] The working principle and process of the ultrasonic vibration composite smart tool holder provided in this embodiment of the invention are as follows: Before machining begins, the intelligent tool holder is first installed onto the tool holder chuck 10 of the machine tool spindle via the tool holder taper shank 21 and locked. The tool electrode 25 is inserted into the chuck 23 and the nut 24 is tightened. The external cooling system pumps coolant into the tool holder through the central water outlet 102. The output of the external ultrasonic generator is connected to the input of the low-pressure micro-arc ultrasonic wireless power-on device 30.

[0030] When machining begins, the machine tool spindle drives the entire intelligent tool holder to rotate. The industrial frequency AC power output from the external ultrasonic generator is converted into an ultrasonic frequency alternating current signal, which is wirelessly transmitted to the ultrasonic vibration device 40 inside the tool holder via the low-voltage micro-arc ultrasonic wireless power-on device 30. The piezoelectric ceramic 42 generates the inverse piezoelectric effect under the excitation of the alternating electric field, converting electrical energy into mechanical vibration of the same frequency. This vibration is amplified by the ultrasonic amplitude transformer 44, driving the tool electrode 25 to perform axial high-frequency vibration relative to the workpiece.

[0031] Simultaneously, the machine tool power supply applies a low-voltage (e.g., 3-30V) high-current between the tool electrode 25 and the workpiece. Under the synergistic effect of high-frequency vibration disturbing the inter-electrode medium and improving chip removal, a stable and uniform low-voltage micro-arc discharge is formed, achieving efficient erosion of difficult-to-machine materials. The force sensor 53, integrated inside the tool holder, monitors cutting force fluctuations in real time during machining and wirelessly transmits the signal to an external monitoring terminal after processing by the circuit board 51. This provides real-time data support for process stability assessment, adaptive adjustment of process parameters, and tool condition evaluation.

[0032] Throughout the processing, the coolant continuously supplied by the central water outlet 102 not only cools and removes chips from the electrical discharge machining area, but also flows around the piezoelectric ceramic components and sensor integration components 50 of the ultrasonic vibration device 40, effectively dissipating heat and ensuring the reliability and lifespan of key components under long-term, high-power operation. The protective cover 60 and the overall insulation design ensure electrical isolation between the main discharge circuit and the internal sensing and vibration units, improving the safety and stability of the system.

[0033] The technical features of the above embodiments can be combined in any way. For the sake of brevity, not all possible combinations of the technical features in the above embodiments are described. However, as long as there is no contradiction in the combination of these technical features, they should be considered to be within the scope of this specification.

[0034] It should be noted that the components mentioned in the above embodiments are all general standard parts or components known to those skilled in the art. Their structures and principles can be learned by those skilled in the art through technical manuals or conventional experimental methods.

[0035] This invention has illustrated its principles and implementation methods using specific examples. The descriptions of these embodiments are merely illustrative of the method and its core ideas; furthermore, those skilled in the art will recognize that modifications may be made to the specific implementation methods and application scope based on the principles of this invention. Therefore, the content of this specification should not be construed as limiting the invention.

Claims

1. An ultrasonic vibration composite intelligent tool holder for low-voltage micro-arc discharge machining, characterized in that, Applications include detachable machine tool spindles, including: The tool holder body is used to connect to the machine tool spindle via a tool holder collet; An ultrasonic vibration device is arranged around the tool holder body to provide high-frequency vibration during the machining process; A sensor integration component is disposed on the tool holder body for monitoring the cutting force during the machining process and transmitting information. A low-voltage micro-arc ultrasonic wireless power supply device is arranged around the tool holder chuck and opposite to the ultrasonic vibration device, and is used to provide power to the ultrasonic vibration device wirelessly.

2. The ultrasonic vibration composite intelligent tool holder for low-voltage micro-arc discharge machining according to claim 1, characterized in that, The main body of the tool holder includes: A tapered shank for connecting to the tool holder collet; A flange is located below the taper shank of the tool holder and is connected to the sensor integration assembly; A fixed end cap is used to fix the ultrasonic vibration device; A clamp is connected to the end of the ultrasonic vibration device; The tool electrode is detachably connected to the chuck.

3. The ultrasonic vibration composite intelligent tool holder for low-voltage micro-arc discharge machining according to claim 2, characterized in that, The tool holder body has a central water outlet hole inside, which is used to deliver coolant and achieve cooling and chip removal.

4. The ultrasonic vibration composite intelligent tool holder for low-voltage micro-arc discharge machining according to claim 2, characterized in that, The main body of the knife handle is covered with a protective cover. The protective cover has screw holes and is fixedly connected to the knife handle taper and sensor integrated assembly by connecting bolts to achieve insulation and sealing.

5. The ultrasonic vibration composite intelligent tool holder for low-voltage micro-arc discharge machining according to claim 3, characterized in that, The ultrasonic vibration device includes: Insulating gaskets; Piezoelectric ceramics are disposed between the insulating pads; An amplitude transformer is connected to the front end of the piezoelectric ceramic. A fixed end cap is used to fix the ultrasonic vibration device to the handle body.

6. The ultrasonic vibration composite intelligent tool holder for low-voltage micro-arc discharge machining according to claim 5, characterized in that, The piezoelectric ceramics are multiple in number and are evenly arranged circumferentially; the insulating gasket, piezoelectric ceramics and amplitude transformer are all provided with through holes that communicate with the central water outlet.

7. The ultrasonic vibration composite intelligent tool holder for low-voltage micro-arc discharge machining according to claim 1, characterized in that, The sensor integration component includes: Force sensor; A circuit board is electrically connected to the force sensor, and the circuit board integrates a signal acquisition module, a data processing module, and a wireless transmission module. A toroidal lithium battery powers the circuit board and the force sensor.

8. The ultrasonic vibration composite intelligent tool holder for low-voltage micro-arc discharge machining according to claim 7, characterized in that, The circuit board is equipped with a charging port for charging the ring-shaped lithium battery; the wireless transmission module is a WiFi module for transmitting processing status information to external devices in real time.

9. The ultrasonic vibration composite intelligent tool holder for low-voltage micro-arc discharge machining according to claim 1, characterized in that, The low-pressure micro-arc ultrasonic wireless power-on device is fixed to the end of the tool holder chuck by connecting bolts, and a gap of 3-5mm is provided between the low-pressure micro-arc ultrasonic wireless power-on device and the tool holder body.

10. The ultrasonic vibration composite intelligent tool holder for low-voltage micro-arc discharge machining according to claim 1, characterized in that, The low-voltage micro-arc ultrasonic wireless power supply device includes a retainer, a positioning extension frame, and a wireless transmitter. The wireless transmitter has a built-in power supply unit for supplying power to the ultrasonic vibration device in a non-contact manner.

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