Laser-ultrasonic energy precise matching processing system and method for PVD (Physical Vapor Deposition) tooth turning blade

Abstract

The invention discloses a PVD tooth turning blade laser-ultrasonic energy precise matching machining system and method. The method comprises the steps that a finite element model is established; modal analysis is conducted on the finite element model, and the inherent frequency and the vibration mode of the finite element model are obtained; a plurality of objective functions are established, wherein the objective functions comprise the maximum tool nose average amplitude, the minimum tool nose amplitude standard deviation and the minimum non-cutting area amplitude; the vibration mode is optimized; performing customized design on the finite element model; processing the finite element model into an actual amplitude-change pole product and a clamp product; performing vibration mode test measurement on the amplitude-change pole product and the clamp product to obtain an amplitude distribution map; the PVD tooth turning blade is machined; in the machining process, amplitude balance compensation is carried out on the PVD tooth turning blade, and self-adaptive tuning is carried out. According to the method, uniform arrangement of vibration nodes and energy of the PVD tooth turning blade is achieved, and the machining precision of the tooth turning blade is improved.

Description

Technical Field

[0001] This application relates to the field of gear cutting tool processing technology, and in particular to a laser-ultrasonic energy precision matching processing system and method for PVD gear cutting inserts. Background Technology

[0002] PVD (Physical Vapor Deposition) cutting inserts are made by depositing an extremely thin (typically a few micrometers) wear-resistant coating on a precision cemented carbide substrate using a PVD process. These inserts have sharp cutting edges and require high tooth profile precision. Their core value lies in their extremely high surface hardness, excellent red hardness, and wear resistance. This makes precision machining of the substrate difficult, and conventional grinding and EDM processes after coating can easily lead to coating peeling, microcracks, or edge dulling, and also fail to meet the requirements of no thermal damage and no mechanical stress.

[0003] In related technologies, PVD turning inserts are processed by a combination of laser and ultrasonic processing. However, due to the complex three-dimensional curved surface, helical grooves and extremely small transition arcs of PVD turning inserts, it is difficult to distribute the vibration nodes and energy evenly during laser-ultrasonic processing of PVD turning inserts, resulting in low processing accuracy and restricting the application of this process to the processing of PVD turning inserts. Summary of the Invention

[0004] This application aims to address at least one of the technical problems existing in the prior art. To this end, this application proposes a laser-ultrasonic energy precision matching machining method for PVD turning inserts, which achieves uniform arrangement of vibration nodes and energy in PVD turning inserts, thereby improving the machining accuracy of turning inserts with features such as three-dimensional spatial curved surfaces, helical grooves, and extremely small transition arcs.

[0005] This application also proposes a laser-ultrasonic energy precision matching machining system for PVD turning inserts.

[0006] The laser-ultrasonic energy precision matching machining method for PVD turning inserts according to the first aspect of this application includes: A finite element model is established, which includes an amplitude transformer, a clamp, a blade, and a transducer. The clamp is located at the output end of the amplitude transformer, the blade is clamped in the clamp, and the transducer is connected to the amplitude transformer. Modal analysis was performed on the finite element model to obtain multiple natural frequencies and corresponding mode shapes of the finite element model in the target frequency band; Multiple objective functions are established, including maximizing the average amplitude of the tool tip, minimizing the standard deviation of the tool tip amplitude, and minimizing the amplitude in the non-cutting region; Optimizing the mode shape includes: using all the objective functions as the objective and the material distribution of the amplitude transformer and the fixture as the first design variable, solving for the material layout of the amplitude transformer and the fixture; using the maximization of the average amplitude of the tool tip and the minimization of the standard deviation of the tool tip amplitude as the objective and the geometric parameters of the amplitude transformer as the second design variable, solving for the shape of the amplitude transformer. Customized design is performed on the finite element model after mode shape optimization, including: smoothing the surfaces of the amplitude transformer and the fixture; and designing a combined longitudinal and torsional vibration for the amplitude transformer. The customized finite element model is then processed into actual amplitude transformer and fixture products. Vibration mode test measurements were performed on the amplitude transformer product and the fixture product to obtain the amplitude distribution spectrum of the qualified amplitude transformer product and the fixture product when processing PVD turning tooth cutting inserts; Install the qualified amplitude rod product and the fixture product, and process the PVD turning tooth cutting insert; During the processing, based on the amplitude distribution spectrum, amplitude equalization compensation is performed on the regions of the PVD turning insert where the amplitude is too large or too small, and adaptive tuning is performed.

[0007] The laser-ultrasonic energy precision matching machining method for PVD turning inserts according to the embodiments of this application has at least the following beneficial effects: In this application, with the objectives of maximizing the average amplitude of the tool tip, minimizing the standard deviation of the tool tip amplitude, and minimizing the amplitude of the non-cutting region, topology optimization and shape optimization are employed to solve for the optimal material layout and shape scheme. This results in an optimized ideal vibration mode with uniform and consistent phase of vibration displacement at the tool tip and the front and rear face. Thus, the uniform arrangement of vibration nodes and energy of the PVD turning insert can be effectively achieved during the design phase. Furthermore, during the machining process, amplitude equalization compensation is performed on areas of excessive or insufficient amplitude of the PVD turning insert based on the amplitude distribution spectrum, and adaptive tuning is performed. This effectively achieves the uniform arrangement of vibration nodes and energy of the PVD turning insert during the machining phase, improving the machining accuracy, fatigue strength, and lifespan of turning inserts with features such as three-dimensional curved surfaces, helical grooves, and extremely small transition arcs. This lays a solid foundation for achieving consistent and high-quality laser-ultrasonic composite machining on turning inserts with complex geometries.

[0008] According to some embodiments of this application, the average amplitude of the blade tip is expressed as: , In the formula, This represents the amplitude of one point on the tip of the blade, and N represents the N points on the tip of the blade. The standard deviation of the blade tip amplitude is expressed as: , The amplitude of the non-cutting region is expressed as: .

[0009] According to some embodiments of this application, the step of solving for the material layout of the amplitude rod and the fixture, with all the objective functions as the objective and the material distribution of the amplitude rod and the fixture as the first design variable, includes: Divide the amplitude rod and the clamp into n There are 1 unit, and the first design variable is represented as: X = [ , ,..., ] , In the formula, This represents the relative density of each element in the finite element model, 0 < ≤ ≤ 1, This represents the lower limit of relative density. n A positive integer representing the number of units; Solve for the first design variable, such that = [ , ] To reach the minimum value, where, = , = , = ; When solving for the first design variable, the constraints set include: = / v*≤ 0, In the formula, This represents the structural volume after optimization of the finite element model. v* represents the initial volume of the finite element model, and v* represents the preset coefficient. = ≤ 0, In the formula, This represents the equivalent stress in the structure after optimization by the finite element model. Indicates the yield strength of the material. This represents the safety factor.

[0010] According to some embodiments of this application, when solving for the first design variable, the calculation function is... , , , and The derivative of the first design variable X is used to guide the optimization direction.

[0011] According to some embodiments of this application, the step of maximizing the average amplitude of the tool tip and minimizing the standard deviation of the tool tip amplitude, with the geometric parameters of the amplitude transformer as the second design variable, and solving for the shape of the amplitude transformer includes: The second design variable is represented as: θ = [ , ,..., ] , in, The geometric parameters of the amplitude transformer are described. n A positive integer indicates that it has n The geometric parameters are of different types; Solve for the second design variable, such that Reaching the maximum value, where, >0; When solving for the second design variable, the constraints set include: ≤ ≤ , In the formula, and These represent the lower and upper limits of the second design variable, respectively. ≤ 0, In the formula, This represents the increase in volume after the finite element model is optimized; =| | Δ ≤ 0, In the formula, This represents the system resonance frequency after optimization of the finite element model. Indicates the target frequency, Δ This indicates the preset frequency deviation value; ≤ 0, In the formula, This represents the equivalent stress in the structure after optimization by the finite element model; MAC(Φ(θ), )≤ 0, In the formula, MAC(Φ(θ), ) represents the optimized mode shape Φ(θ) and the ideal mode shape of the finite element model. Modal confidence between This indicates a preset threshold.

[0012] According to some embodiments of this application, when solving for the second design variable, the calculation function is... , , , and For the second design variable The derivative of is used to guide the direction of optimization.

[0013] According to some embodiments of this application, the longitudinal-torsional composite vibration design of the amplitude transformer includes: Non-axisymmetric grooves or diagonal cracks are machined on the outer peripheral wall of the amplitude transformer; and / or, The outer peripheral wall of the amplitude transformer is configured to have a non-axisymmetric shape; and / or, The polarization direction of a portion of the piezoelectric ceramic sheet of the transducer is rotated by 90°.

[0014] According to some embodiments of this application, the step of performing amplitude equalization compensation and adaptive tuning on regions of excessively large or small amplitude of the PVD turning tooth cutting tool based on the amplitude distribution spectrum includes: For regions where the amplitude of the PVD cutting tool is less than a preset amplitude range, reduce the laser scanning speed or increase the single pulse energy; For regions where the amplitude of the PVD cutting tool exceeds a preset amplitude range, increase the laser scanning speed or reduce the single pulse energy. When a resonant frequency drift is detected in the PVD cutting tool, the output frequency of the ultrasonic power supply is adjusted. When the actual amplitude of the PVD cutting tool is detected to be attenuated, the actual amplitude is maintained within a preset range through closed-loop power control.

[0015] According to some embodiments of this application, the following steps are also included: The PVD cutting insert is divided into multiple processing zones, and different processing parameters are set for positions with different vibration characteristics within the same processing zone.

[0016] The PVD turning tool laser-ultrasonic energy precision matching machining system according to the second aspect of this application includes: The model building module is used to build a finite element model, which includes an amplitude transformer, a clamp, a blade, and a transducer. The clamp is located at the output end of the amplitude transformer, the blade is clamped in the clamp, and the transducer is connected to the amplitude transformer. The modal analysis module is used to perform modal analysis on the finite element model to obtain multiple natural frequencies and corresponding mode shapes of the finite element model in the target frequency band. The objective function establishment module is used to establish multiple objective functions, including maximizing the average amplitude of the tool tip, minimizing the standard deviation of the tool tip amplitude, and minimizing the amplitude in the non-cutting region. A mode shape optimization module is used to optimize the mode shape; A customized design module is used to perform customized design on the finite element model after the mode shape optimization; The mode shape measurement module is used to perform mode shape test measurements on the customized finite element model and obtain the amplitude distribution spectrum of the finite element model that has passed the measurement. A machining device is used to install tooling made according to the measured and qualified finite element model, and to machine PVD turning tooth inserts; The processing device is also used to perform amplitude equalization compensation for areas where the amplitude of the PVD turning tooth cutting tool is too large or too small based on the amplitude distribution spectrum during the processing, and to perform adaptive tuning.

[0017] Other features and advantages of this application will be set forth in the following description, and will be apparent in part from the description, or may be learned by practicing this application. Attached Figure Description

[0018] The above and / or additional aspects and advantages of this application will become apparent and readily understood from the description of the embodiments taken in conjunction with the following drawings, in which: Figure 1 This is a schematic flowchart of the laser-ultrasonic energy precision matching processing method for PVD turning inserts according to an embodiment of this application; Figure 2 This is a schematic diagram of the laser-ultrasonic energy precision matching machining system for PVD turning inserts according to an embodiment of this application. Detailed Implementation

[0019] To make the objectives, technical solutions, and advantages of this application clearer, the following detailed description is provided in conjunction with the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are merely illustrative and not intended to limit the scope of this application.

[0020] It should be noted that although functional modules are divided in the device schematic diagram and a logical order is shown in the flowchart, in some cases, the steps shown or described may be performed in a different order than the module division in the device or the order in the flowchart. The terms "first" and "second," etc., in the specification, claims, and the aforementioned drawings are used to distinguish similar objects and are not necessarily used to describe a specific order or sequence.

[0021] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this application belongs. The terminology used herein is for the purpose of describing embodiments of this application only and is not intended to limit this application.

[0022] refer to Figure 1 As shown, the laser-ultrasonic energy precision matching machining method for PVD turning inserts according to the first aspect of this application includes, but is not limited to, the following steps: A finite element model is established, which includes an amplitude transformer, a clamp, a blade, and a transducer. The clamp is located at the output end of the amplitude transformer, the blade is clamped in the clamp, and the transducer is connected to the amplitude transformer. Modal analysis was performed on the finite element model to obtain multiple natural frequencies and corresponding mode shapes of the finite element model in the target frequency band; Multiple objective functions are established, including maximizing the average amplitude of the tool tip, minimizing the standard deviation of the tool tip amplitude, and minimizing the amplitude in the non-cutting region; The mode shape is optimized by: taking all objective functions as the objective and the material distribution of the amplitude rod and fixture as the first design variable, solving for the material layout of the amplitude rod and fixture; taking maximizing the average amplitude of the tool tip and minimizing the standard deviation of the tool tip amplitude as the objective and the geometric parameters of the amplitude rod as the second design variable, solving for the optimal shape of the amplitude rod. Customized design was carried out on the finite element model after mode shape optimization, including: smoothing the surfaces of the amplitude transformer and the fixture; and designing the amplitude transformer for combined longitudinal and torsional vibration. Customized finite element models are processed into actual amplitude transformer and fixture products; Vibration mode tests were conducted on the amplitude transformer and fixture products to obtain the amplitude distribution spectrum of the qualified amplitude transformer and fixture products when machining PVD turning tooth cutting inserts; Install qualified amplitude transformer and fixture products, and process PVD gear cutting inserts; During the machining process, amplitude equalization compensation is performed on areas of excessive or insufficient amplitude of the PVD cutting insert based on the amplitude distribution spectrum, and adaptive tuning is also performed.

[0023] This application presents a laser-ultrasonic energy precision matching machining method for PVD turning inserts. To maximize the average amplitude of the tool tip, minimize the standard deviation of the tool tip amplitude, and minimize the amplitude in the non-cutting region, topology optimization and shape optimization are employed to solve for the optimal material layout and shape scheme. This results in an optimized ideal vibration mode with uniform and phase-consistent vibration displacement of the tool tip and the front and rear facets. Thus, uniform arrangement of vibration nodes and energy in the PVD turning insert can be effectively achieved during the design phase. Furthermore, during machining, amplitude equalization compensation is performed on areas of excessive or insufficient amplitude in the PVD turning insert based on the amplitude distribution spectrum, and adaptive tuning is implemented. This effectively achieves uniform arrangement of vibration nodes and energy in the PVD turning insert during the machining phase, improving the machining accuracy, fatigue strength, and lifespan of PVD turning inserts with features such as three-dimensional curved surfaces, helical grooves, and extremely small transition arcs. This lays a solid foundation for achieving consistent, high-quality laser-ultrasonic composite machining on PVD turning inserts with complex geometries.

[0024] The following is a detailed description of the laser-ultrasonic energy precision matching processing method for PVD turning inserts in this application.

[0025] Before performing the actual PVD machining of the gear cutting inserts, high-fidelity modal simulation and vibration system design are first carried out, as follows: In some embodiments of this application, a high-precision finite element model is first established. The primary step is to establish a high-precision finite element model of the real three-dimensional geometry of the transducer, amplitude transformer, flange, fixture, and cutting tool (PVD gear cutting tool blank). The fixture is located at the output end of the amplitude transformer, the cutting tool is clamped in the fixture, the transducer is connected to the amplitude transformer, and the flange can be connected to a node of the amplitude transformer. Precise material parameters (density, elastic modulus, Poisson's ratio, and damping coefficient) need to be assigned to each component, and the piezoelectric matrix of the transducer's piezoelectric ceramic is defined. Simultaneously, fixed constraint boundary conditions are set at the flange location to accurately simulate the rigid support state under actual working conditions.

[0026] In some embodiments of this application, modal analysis and resonant frequency prediction are then performed. After the model is built, modal analysis and resonant frequency prediction are required. By solving the natural frequencies and mode shapes of the entire system in the 20-40kHz target frequency band of the finite element model, the efficiency of vibration energy transfer to the cutting edge region is analyzed. The key objective is to obtain an ideal mode shape with uniform and phase-consistent vibration displacement of the tool tip and rake face, while avoiding energy concentration caused by local modes, ensuring a balanced distribution of vibration energy on the complex geometry of the tool, so that the vibration energy can be transferred to the cutting edge region of the insert to the maximum extent. The ideal mode shape is that the tool tip, rake face, and flank face all have considerable and phase-consistent vibration displacement. It is ensured that the insert itself does not exhibit local modes, i.e., a certain tooth or a certain local area vibrates abnormally violently while other areas remain almost still.

[0027] In some embodiments of this application, the specific process for obtaining the ideal mode shape is as follows: First, parametric analysis and modal scanning are performed using finite element software. After constructing a high-precision finite element model, parametric analysis and modal scanning of the finite element model in the target frequency band of 20-40kHz are conducted using the modal analysis modules of professional finite element software such as ANSYS and ABAQUS. This process automatically calculates and outputs a series of natural frequencies and their corresponding mode shapes within this frequency band by solving for the system's eigenvalues ​​and eigenvectors. The built-in post-processor directly obtains all possible mode shape contour maps and dynamic visualization results, providing a complete data foundation for subsequent mode shape selection and optimization.

[0028] Second, establish quantifiable objective functions for mode shape selection and optimization. Clear and calculable indices need to be defined for the ideal mode shape. During mode shape optimization, three key objective functions need to be established to guide the optimization direction: The primary objective is to maximize the average amplitude of the blade tip, which is expressed as: , In the formula, This represents the amplitude at one point on the blade tip, and N represents the N points on the blade tip. By increasing the overall vibration intensity of the tool tip group to ensure that the cutting edge receives sufficient energy, the core objective is to optimize the uniformity of the amplitude distribution and achieve consistency of machining conditions for each tooth by minimizing the standard deviation of the tool tip amplitude. The standard deviation of the blade tip amplitude is expressed as: , The auxiliary objective is to suppress vibration in the non-working area, which is achieved by minimizing the amplitude in the non-cutting region to improve energy transfer efficiency. The amplitude in the non-cutting region is expressed as... .

[0029] In this way, the vibration energy is concentrated on the cutting edge region, thereby comprehensively improving the system's energy utilization efficiency. These three interrelated objective functions together constitute the quantitative evaluation system for mode shape optimization.

[0030] Third, topology optimization and shape optimization techniques are used.

[0031] Phase 1 optimization: Topology optimization. Using the average amplitude of the blade tip... Maximize, amplitude standard deviation Minimize and non-working area amplitude Minimization is used as the constraint, and the material distribution of the amplitude rod and clamps is taken as the first design variable. An iterative algorithm is employed to find the optimal material layout that satisfies the structural strength requirements. This mathematical programming-based method can generate innovative configurations that are difficult to obtain through traditional empirical design. The topology optimization is detailed below: Divide the amplitude lever and fixture into n units, and establish the first design variable, represented as: X = [ , ,..., ] , In the formula, This represents the relative density of each element in the finite element model, 0 < ≤ ≤1, This represents the lower limit of the relative density, where n is a positive integer representing the number of units; Solve for the first design variable, such that = [ , ] To reach the minimum value, where, = , = , = ; In the formula, = This is because optimization algorithms typically assume a minimization problem, so taking a negative value transforms a maximization problem into a minimization problem.

[0032] When solving for the first design variable, the constraints set include: Volume constraints: = / v*≤0, In the formula, This represents the structural volume after optimization using the finite element model. v* represents the initial volume of the finite element model, and v* represents the preset coefficients, which is the optimized structural volume of the finite element model. Cannot exceed the initial volume A certain proportion of v* is used to control the amount of material used; Strength constraint conditions: = ≤0, In the formula, This represents the equivalent stress in the structure after optimization by the finite element model. Indicates the yield strength of the material. This represents the safety factor, which is the equivalent stress in the structure after optimization by the finite element model. It must be less than the yield strength of the material. Divide by safety factor To ensure mechanical reliability.

[0033] It should be noted that the constraints can also include manufacturing constraints: constraints such as minimum member size and draft direction can be added to ensure the manufacturability of the optimization results.

[0034] Multi-objective function handling: Weighted sum methods or Pareto front methods are typically used to handle multiple objective functions. For example, a multi-objective problem can be transformed into a single-objective problem. = + + , , and Weighting coefficients set based on performance preferences.

[0035] In addition, sensitivity analysis can be performed during the solution process, i.e., the function can be calculated. , , , and The derivative with respect to the first design variable X is used to guide the optimization direction. Commonly used algorithms include the variable density method and the level set method.

[0036] Based on this, the second stage of optimization is carried out: shape optimization.

[0037] Further fine-tuning of the geometric parameters, such as the profile curve and transition radius R of the amplitude transformer, is performed to regulate the mode shape distribution, thereby effectively eliminating local modes on the cutting edge and achieving precise transmission of vibration energy to the cutting edge. This optimization model aims to further optimize the vibration performance of the system by fine-tuning the given geometry, while satisfying all engineering constraints; it is a parametric optimization problem. The specific shape optimization is as follows: Establish a second design variable, represented as: θ=[ , ,..., ] , in, This represents the geometric parameters of the amplitude transformer, where n is a positive integer, indicating that there are n different types of geometric parameters, for example, It can be the radius of the transition arc between two adjacent arc surfaces of the amplitude transformer. It could be the length of the working section of the amplitude transformer, and other variables could be the coordinates of multiple control points on the control profile curve or spline curve parameters, etc. Solve for the second design variable, such that Reaching the maximum value, where, >0, It can be a very small positive integer to prevent the denominator from being 0; the objective function aims to simultaneously pursue a high average amplitude and a low amplitude standard deviation. The better the amplitude uniformity (…), the better the amplitude uniformity. The smaller the value, the better. The larger the value, the better it is, thus guiding the direction of optimization.

[0038] When solving for the second design variable, the constraints set include: Geometric constraints: ≤ ≤ , In the formula, and These represent the lower and upper limits of the second design variable, respectively, to ensure that the shape is within a reasonable manufacturing and spatial range; Volume constraints: ≤ 0, In the formula, This indicates the increase in volume after optimization of the finite element model, preventing excessive material addition. Performance constraints: =| | Δ ≤0, In the formula This represents the system resonance frequency after optimization of the finite element model. Indicates the target frequency (e.g., the optimal frequency of the ultrasonic power source), Δ This indicates the preset frequency deviation value, which is the deviation between the optimized system resonant frequency and the target frequency within the allowable range Δ. Inside.

[0039] ≤0, In the formula, This represents the equivalent stress in the structure after optimization using the finite element model. It must be less than the yield strength of the material. Divide by safety factor To ensure mechanical reliability; MAC(Φ(θ), )≤0, In the formula, MAC(Φ(θ), ) represents the optimized mode shape Φ(θ) and the ideal mode shape of the finite element model. Modal confidence between This indicates a preset threshold, meaning the modal confidence level between the optimized mode shape and the ideal mode shape in the finite element model must be higher than the preset threshold in order to effectively suppress local modes.

[0040] In addition, sensitivity analysis can be performed during the solution process, i.e., the function can be calculated. , , , and For the second design variable The derivative of the second design variable is used to guide the optimization direction, which is usually implemented in finite element software using the adjoint variable method or the direct difference method. The iterative process employs optimization algorithms, such as sequential quadratic programming or moving asymptote method, and uses sensitivity information to determine the search direction and update the second design variable in each iteration until the optimal solution that satisfies all constraints is found.

[0041] In some embodiments of this application, customized designs are performed for the amplitude transformer and the fixture. Based on the simulation analysis and optimization results of the previous embodiments, after obtaining the amplitude transformer vibration mode, customized designs for the amplitude transformer and the fixture need to be carried out. A topology optimization method aimed at maximizing the tip amplitude and minimizing the difference in blade amplitude is adopted, and a performance-driven complex profile structure is obtained through iterative optimization. In particular, longitudinal-torsional composite vibration is achieved by designing oblique grooves, oblique cracks, or using a combination of heteropolarized piezoelectric ceramics. The longitudinal vibration is converted into a torsional component, and the shearing action generated by it effectively cleans the side blades and promotes chip removal in the spiral groove, thereby achieving a technological upgrade from single-dimensional to multi-dimensional coordinated vibration.

[0042] Customized design includes geometric reconstruction and process adaptation, as detailed below: The abstract cloud map obtained from topology optimization is transformed into a manufacturable, parametric 3D CAD model. This involves smoothing the rough surfaces generated during optimization to eliminate stress concentration points. Furthermore, considering the capabilities of 3D printing (metal additive manufacturing) or five-axis CNC machining, subtle features are appropriately adjusted to ensure stable manufacturing.

[0043] In addition, the customized design also includes a combined longitudinal and torsional vibration design for the amplitude transformer, which is achieved through a combination of the following two methods: First, structural design implementation: First, non-axisymmetric grooves can be machined on the outer peripheral wall of the amplitude transformer, such as helical grooves at a specific angle, or non-axisymmetric diagonal cracks can be machined on the outer peripheral wall of the amplitude transformer. When longitudinal vibration waves propagate to this structure, they will be decomposed into a continuing longitudinal component and a torsional component that deflects.

[0044] Secondly, the outer periphery of the amplitude transformer can be set to a non-axisymmetric shape. For example, a section of the amplitude transformer can be designed as a non-axisymmetric polygon or a specific curved surface, and its asymmetric stiffness can be used to couple vibration modes.

[0045] Second, this is achieved by adjusting the polarization of the piezoelectric ceramic sheet in the transducer: In the transducer, the traditional approach of aligning the polarization directions of all piezoelectric ceramic sheets is no longer used. Instead, the polarization directions of some ceramic sheets are rotated by 90°. When the same high-frequency power supply is applied, some ceramic sheets mainly undergo longitudinal expansion and contraction, while others mainly undergo shear deformation, thereby directly exciting longitudinal-torsional composite vibrations at the source.

[0046] In some embodiments of this application, detailed modal verification and shape optimization are performed, as follows: Modal analysis is performed again on the reconstructed CAD model to verify whether its mode shapes and frequencies meet the initial targets. If not, the model enters the shape optimization stage, where geometric parameters such as the contour curves and transition fillets are fine-tuned until the simulation results meet the requirements.

[0047] In some embodiments of this application, prototype manufacturing and experimental verification are carried out, as detailed below: Customized amplitude transformers and fixtures are manufactured using precision wire EDM or metal 3D printing technology. Actual measurements are performed using a laser vibrometer, and the obtained actual amplitude distribution is compared with simulation results to calculate modal confidence. If the consistency is high, the design is successful; if deviations exist, the finite element model needs to be revised.

[0048] In some embodiments of this application, amplitude distribution spectra are obtained based on mode shape measurements, as detailed below: Accurate vibration characteristic data were obtained through experimental measurements. A laser scanning Doppler vibrometer was used as the core measuring tool. With the ultrasonic system operating at the target resonant frequency, the laser measuring points were controlled to perform high-speed scanning of the PVD cutting tool surface (especially all cutting edge areas). This method yields a complete amplitude distribution spectrum, which visually presents the vibration intensity distribution characteristics at various spatial locations on the tool surface, providing an accurate data foundation for subsequent analysis.

[0049] In some embodiments of this application, after obtaining experimental data, model verification and calibration are carried out, as follows: A systematic comparative analysis is conducted between the measured amplitude distribution spectrum and the finite element simulation results. If significant differences are found, key parameters such as material damping characteristics and boundary conditions in the finite element model need to be corrected based on the measured data. This data-driven iterative optimization process ensures a high degree of consistency between the digital twin model and the physical entity, providing reliable theoretical model support for subsequent process optimization.

[0050] In some embodiments of this application, a qualified amplitude transformer and fixture are installed, and PVD turning inserts are machined. Specifically, the qualified amplitude transformer and fixture are installed on the insert machining module 800, for example, on a laser processing machine tool.

[0051] In some embodiments of this application, during the processing, amplitude equalization compensation is performed on areas of excessive or insufficient amplitude in the PVD turning insert based on the amplitude distribution spectrum, specifically including: Amplitude equalization algorithm. To achieve a uniform distribution of vibration energy on the tool surface, the system employs an intelligent equalization algorithm based on amplitude distribution maps. This algorithm takes measured full-field amplitude data as input and automatically identifies areas with excessive or insufficient amplitude. Precise compensation is then applied to different areas: in areas with insufficient amplitude, positive compensation is performed according to the material removal rate model by reducing the laser scanning speed or increasing the single-pulse energy; in areas with excessive amplitude, the opposite strategy is adopted, suppressing excessive ablation by increasing the laser scanning speed or reducing the single-pulse energy. This synergistic control strategy of optical vibration compensation and optical vibration suppression effectively eliminates machining quality differences caused by uneven vibration.

[0052] In some embodiments of this application, adaptive tuning is performed in real time during processing, specifically including: During machining, as material is removed, the mass and stiffness distribution of the cutting tool undergoes slight changes, leading to drift in its resonant frequency and mode shape. To address the stability issues caused by changes in system dynamics during machining, the system is equipped with a real-time adaptive tuning mechanism. As the mass and stiffness distribution of the cutting tool changes due to material removal, the system monitors the transducer current phase characteristics or fixed-point amplitude to identify resonant frequency drift and amplitude attenuation in real time. The control algorithm dynamically adjusts the ultrasonic power supply output frequency accordingly, ensuring it always tracks the system's optimal resonant point. Simultaneously, closed-loop power control maintains the actual amplitude stable at the set value, ensuring continuous stability of vibration energy output during machining. The system continuously monitors the current and phase feedback from the piezoelectric transducer, or uses a fixed single-point vibrometer to monitor the amplitude at a reference point. Once resonant frequency drift or amplitude attenuation is detected, the control algorithm automatically fine-tunes the ultrasonic power supply output frequency, keeping it locked at the system's optimal resonant point. Simultaneously, closed-loop power control ensures stable transducer input power, thereby maintaining a constant amplitude.

[0053] In some embodiments of this application, vibration-adaptive mapping of process parameters is performed during the processing, specifically including: To achieve precise control of the machining process, vibration characteristics must be deeply integrated into the process system. A multi-level parameter architecture should be constructed in the process database. This not only defines dedicated parameter packages for different geometric features of different machining zones, but also further subdivides micro-parameter strategies based on vibration intensity distribution within the same machining zone. For example, an amplitude adaptive sub-strategy can be set in the parameter package of the flank face region. When the amplitude of the machining area is greater than 0.4μm, standard process parameters are used, while when the amplitude is in the 0.2-0.4μm range, the laser power is increased to 105% of the standard power. This dynamic coupling of vibration and laser parameters achieves precise matching of energy input.

[0054] refer to Figure 2 As shown in the embodiment of this application, a laser-ultrasonic energy precision matching machining system for PVD turning inserts is also provided, including a model building module 100, a modal analysis module 200, an objective function establishment module 300, a mode shape optimization module 400, a customized design module 500, a tooling machining module 600, a mode shape measurement module 700, and an insert machining module 800.

[0055] The model building module 100 is used to build a finite element model, which includes an amplitude transformer, a fixture, a blade, and a transducer. The fixture is located at the output end of the amplitude transformer, the blade is clamped in the fixture, and the transducer is connected to the amplitude transformer. The modal analysis module 200 is used to perform modal analysis on the finite element model to obtain multiple natural frequencies and corresponding mode shapes of the finite element model in the target frequency band. The objective function establishment module 300 is used to establish multiple objective functions, including maximizing the average amplitude of the tool tip, minimizing the standard deviation of the tool tip amplitude, and minimizing the amplitude in the non-cutting region; The mode shape optimization module 400 is used to optimize mode shapes; The customized design module 500 is used to perform customized design on the finite element model after mode shape optimization; The tooling processing module 600 is used to process customized finite element models into actual amplitude transformer products and fixture products; The mode shape measurement module 700 is used to perform mode shape test measurements on amplitude transformer products and fixture products, and to obtain the amplitude distribution spectrum of the qualified amplitude transformer products and fixture products when processing PVD turning tooth cutting inserts; The cutting tool processing module 800 is used to install qualified amplitude transformer products and fixture products, and to process PVD cutting tool inserts; the cutting tool processing module 800 is also used to perform amplitude equalization compensation for areas with excessive or insufficient amplitude of PVD cutting tool inserts based on amplitude distribution spectrum during the processing, and to perform adaptive tuning.

[0056] It should be noted that since the PVD tooth cutting insert laser-ultrasonic energy precision matching processing system of this application embodiment and the PVD tooth cutting insert laser-ultrasonic energy precision matching processing method of the above embodiment are based on the same inventive concept, the corresponding content and beneficial effects in the method embodiment are also applicable to the system embodiment, and will not be described in detail here.

[0057] The system embodiments described above are merely illustrative. The units described as separate components may or may not be physically separate; that is, they may be located in one place or distributed in multiple locations. Some or all of the units can be selected to achieve the purpose of this embodiment according to actual needs.

[0058] The embodiments of this application have been described in detail above with reference to the accompanying drawings. However, this application is not limited to the above embodiments. Within the scope of knowledge possessed by those skilled in the art, various changes can be made without departing from the spirit of this application.

Claims

1. A method for precise matching of laser and ultrasonic energy in the machining of PVD tooth cutting inserts, characterized in that, include: A finite element model is established, which includes an amplitude transformer, a clamp, a blade, and a transducer. The clamp is located at the output end of the amplitude transformer, the blade is clamped in the clamp, and the transducer is connected to the amplitude transformer. Modal analysis was performed on the finite element model to obtain multiple natural frequencies and corresponding mode shapes of the finite element model in the target frequency band; Multiple objective functions are established, including maximizing the average amplitude of the tool tip, minimizing the standard deviation of the tool tip amplitude, and minimizing the amplitude in the non-cutting region; Optimizing the mode shape includes: using all the objective functions as the objective and the material distribution of the amplitude transformer and the fixture as the first design variable, solving for the material layout of the amplitude transformer and the fixture; using the maximization of the average amplitude of the tool tip and the minimization of the standard deviation of the tool tip amplitude as the objective and the geometric parameters of the amplitude transformer as the second design variable, solving for the shape of the amplitude transformer. Customized design is performed on the finite element model after mode shape optimization, including: smoothing the surfaces of the amplitude transformer and the fixture; and designing a combined longitudinal and torsional vibration for the amplitude transformer. The customized finite element model is then processed into actual amplitude transformer and fixture products. Vibration mode test measurements were performed on the amplitude transformer product and the fixture product to obtain the amplitude distribution spectrum of the qualified amplitude transformer product and the fixture product when processing PVD turning tooth cutting inserts; Install the qualified amplitude transformer and the fixture product, and process the PVD gear cutting insert; During the processing, based on the amplitude distribution spectrum, amplitude equalization compensation is performed on the regions of the PVD turning insert where the amplitude is too large or too small, and adaptive tuning is performed.

2. The laser-ultrasonic energy precision matching machining method for PVD turning inserts according to claim 1, characterized in that, The average amplitude of the blade tip is expressed as: ， In the formula, This represents the amplitude of one point on the tip of the blade, and N represents the N points on the tip of the blade. The standard deviation of the blade tip amplitude is expressed as: ， The amplitude of the non-cutting region is expressed as: .

3. The laser-ultrasonic energy precision matching machining method for PVD turning inserts according to claim 2, characterized in that, The process of solving for the material layout of the amplitude transformer and the fixture, with all the objective functions as the objective and the material distribution of the amplitude transformer and the fixture as the first design variable, includes: Divide the amplitude rod and the clamp into n There are 1 unit, and the first design variable is represented as: X = [ ， ，...， ] ， In the formula, Represents the relative density of each of the units, 0 < ≤ ≤ 1, This represents the lower limit of the relative density. n A positive integer representing the number of units; Solve for the first design variable, such that = [ , ] To reach the minimum value, where, = ， = ， = ； When solving for the first design variable, the constraints set include: = / v*≤ 0， In the formula, This represents the structural volume after optimization of the finite element model. v* represents the initial volume of the finite element model, and v* represents the preset coefficient. = ≤ 0， In the formula, This represents the equivalent stress in the structure after optimization by the finite element model. Indicates the yield strength of the material. This represents the safety factor.

4. The laser-ultrasonic energy precision matching machining method for PVD turning inserts according to claim 3, characterized in that, When solving for the first design variable, the calculation function is... , , , and The derivative of the first design variable X is used to guide the optimization direction.

5. The laser-ultrasonic energy precision matching machining method for PVD turning inserts according to claim 2, characterized in that, The objective is to maximize the average amplitude of the cutting edge and minimize the standard deviation of the cutting edge amplitude. The geometric parameters of the amplitude transformer are the second design variable. Solving for the shape of the amplitude transformer includes: The second design variable is represented as: θ = [ , ,..., ] , in, The geometric parameters of the amplitude transformer are described. n A positive integer indicates that it has n The geometric parameters are of different types; Solve for the second design variable, such that Reaching the maximum value, where, >0; When solving for the second design variable, the constraints set include: ≤ ≤ ， In the formula, and These represent the lower and upper limits of the second design variable, respectively. ≤ 0， In the formula, This represents the increase in volume after the finite element model is optimized; =| | D ≤ 0, In the formula, This represents the system resonance frequency after optimization of the finite element model. Indicates the target frequency, Δ This indicates the preset frequency deviation value; ≤ 0， In the formula, This represents the equivalent stress in the structure after optimization by the finite element model. Indicates the yield strength of the material. Indicates the safety factor; MAC(Φ(θ), )≤ 0, In the formula, MAC(Φ(θ), ) represents the optimized mode shape Φ(θ) and the ideal mode shape of the finite element model. Modal confidence between This indicates a preset threshold.

6. The laser-ultrasonic energy precision matching machining method for PVD turning inserts according to claim 5, characterized in that, When solving for the second design variable, the calculation function is... , , , and For the second design variable The derivative of is used to guide the direction of optimization.

7. The laser-ultrasonic energy precision matching machining method for PVD turning inserts according to claim 1, characterized in that, The longitudinal-torsional combined vibration design of the amplitude transformer includes: Non-axisymmetric grooves or diagonal cracks are machined on the outer peripheral wall of the amplitude transformer; and / or, The outer peripheral wall of the amplitude transformer is configured to have a non-axisymmetric shape; and / or, The polarization direction of a portion of the piezoelectric ceramic sheet of the transducer is rotated by 90°.

8. The laser-ultrasonic energy precision matching machining method for PVD turning inserts according to claim 1, characterized in that, The step of performing amplitude equalization compensation and adaptive tuning based on the amplitude distribution spectrum for regions of excessive or insufficient amplitude of the PVD cutting tool includes: For regions where the amplitude of the PVD cutting tool is less than a preset amplitude range, reduce the laser scanning speed or increase the single pulse energy; For regions where the amplitude of the PVD cutting tool exceeds a preset amplitude range, increase the laser scanning speed or reduce the single pulse energy. When a resonant frequency drift is detected in the PVD cutting tool, the output frequency of the ultrasonic power supply is adjusted. When the actual amplitude of the PVD cutting tool is detected to be attenuated, the actual amplitude is maintained within a preset range through closed-loop power control.

9. The laser-ultrasonic energy precision matching machining method for PVD turning inserts according to claim 1, characterized in that, It also includes the following steps: The PVD cutting insert is divided into multiple processing zones, and different processing parameters are set for positions with different vibration characteristics within the same processing zone.

10. A laser-ultrasonic energy precision matching machining system for PVD turning inserts, characterized in that, include: The model building module is used to build a finite element model, which includes an amplitude transformer, a clamp, a blade, and a transducer. The clamp is located at the output end of the amplitude transformer, the blade is clamped in the clamp, and the transducer is connected to the amplitude transformer. The modal analysis module is used to perform modal analysis on the finite element model to obtain multiple natural frequencies and corresponding mode shapes of the finite element model in the target frequency band. The objective function establishment module is used to establish multiple objective functions, including maximizing the average amplitude of the tool tip, minimizing the standard deviation of the tool tip amplitude, and minimizing the amplitude in the non-cutting region. A mode shape optimization module is used to optimize the mode shape; A customized design module is used to perform customized design on the finite element model after the mode shape optimization; The tooling processing module is used to process the customized finite element model into actual amplitude transformer products and fixture products; The mode shape measurement module is used to perform mode shape test measurements on the amplitude transformer product and the fixture product, and obtain the amplitude distribution spectrum of the amplitude transformer product and the fixture product when processing PVD turning tooth cutting inserts after the measurement is qualified; The cutting tool processing module is used to install the measured and qualified amplitude rod product and the fixture product, and to process the PVD turning tool insert; The cutting tool processing module is also used to perform amplitude equalization compensation for areas where the amplitude of the PVD turning cutting tool is too large or too small based on the amplitude distribution spectrum during the processing, and to perform adaptive tuning.

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