Magnetic field guided ultrasonic machining device and method of a magnetic responsive phase composite material

Abstract

The application belongs to the technical field of special composite machining, and particularly discloses a magnetic field guiding ultrasonic machining device and method for magnetic response phase composite material; in view of the problems of large cutting force, serious tool wear and workpiece damage caused by the random distribution of the reinforcing phase in traditional machining, a high gradient directional magnetic field is generated by a magnetic field generator arranged in the tool or in the vicinity of the tool during the whole process of cutting of the tool on the workpiece, controllable magnetic field force is applied to the magnetic reinforcing phase in the cutting layer material, so that the magnetic reinforcing phase is dynamically deflected, rotated or migrated, and the distribution and orientation of the magnetic reinforcing phase on the cutting path are optimized in real time on the micro scale; at the same time, the tool is driven to perform high-frequency ultrasonic vibration cutting, and the material layer under the guidance of the magnetic field is removed efficiently. The device comprises a machine tool main body, an ultrasonic vibration module, a magnetic field generation module, a special composite tool, a non-contact induction power supply module and a control system.

Description

Technical Field

[0001] This invention belongs to the field of composite processing in special processing technology, and specifically discloses a magnetic field-guided ultrasonic processing device and method for magnetically responsive phase composite materials. Background Technology

[0002] Magnetic particle or magnetic fiber reinforced composite materials are increasingly widely used in aerospace, high-end equipment, and other fields due to their excellent specific strength, specific stiffness, wear resistance, and heat resistance. However, while the hard or high-toughness reinforcing phases (such as alloy particles and metal fibers) improve the material's performance, they also significantly increase the difficulty of machining. When dealing with these materials using traditional milling and drilling methods, the cutting tool directly impacts and rubs against the randomly distributed hard reinforcing phase, resulting in large fluctuations in cutting force, high cutting temperature, and abnormally rapid tool wear. Furthermore, these methods easily cause damage such as cracks, burrs, and holes caused by reinforcing phase pull-out or breakage on the workpiece surface and subsurface, severely affecting the service performance and lifespan of the parts.

[0003] To improve the machining effect of such difficult-to-machine composite materials, existing technologies have introduced magnetic field-assisted machining methods. For example, patent application CN202010077185.1 discloses a method and device for electromagnetic-acoustic multi-field composite-assisted drilling of micro-deep holes. This device includes an ultrasonic vibrating tool holder, an ultrasonic generator, a magnetic field-assisted machining system, copper electrodes, insulating pads, and a pulse power supply. However, the magnetic field assistance focuses on the macroscopic physical effects in the machining area, improving the overall stress state of the material or assisting chip removal through pulsed magnetic fields. It does not involve the active and precise control of the internal microstructure of the workpiece material, especially the spatial distribution and orientation of the reinforcing phase (such as magnetic fibers or particles). Secondly, the device has a complex structure, requiring additional electrodes and magnetic field coils to be arranged in the machining area, occupying space and limiting its application range. Moreover, the magnetic field effect area is dispersed, making it difficult to form a high-gradient, high-intensity directional magnetic field in front of the cutting edge of the tool, thus failing to achieve microscopic manipulation of the reinforcing phase. Therefore, this existing technology is difficult to adapt to the processing methods of materials with existing microstructures, and cannot fundamentally solve the problems of large cutting force fluctuations caused by the random distribution of reinforcing phases, and processing damage and tool wear caused by the direct and intense interaction between reinforcing phases and tools. Summary of the Invention

[0004] To address the shortcomings of existing technologies, this invention proposes a magnetic field-guided ultrasonic machining device and method for magnetically responsive composite materials. During the cutting of the composite material, an externally applied controllable magnetic field is used to act on the magnetically reinforcing phase, causing favorable adjustments to its position and orientation, reducing adverse effects on the cutting tool, and thus improving the material's machinability. Simultaneously, high-frequency ultrasonic vibration is introduced to achieve low-force, high-efficiency shearing removal. The synergistic effect of magnetic field guidance and ultrasonic vibration improves machining quality and efficiency throughout the entire process, from material structure control to cutting removal.

[0005] To achieve the above objectives, the technical solution adopted by the present invention is as follows:

[0006] In a first aspect, the present invention provides a magnetic field-guided ultrasonic machining device for magnetically responsive phase composite materials, comprising an ultrasonic vibration module, a magnetic field generating module, a composite cutting tool, a power supply module, and a control system.

[0007] The composite cutting tool has an internal cavity;

[0008] The magnetic field generating module is located inside the cavity and includes at least one set of excitation coils and a magnetic conductor. Some of the excitation coils are wound on the magnetic conductor. The magnetic conductor is embedded in the front end of the tool and close to the cutting edge area to generate a directional and controllable magnetic field with a set intensity and gradient in the working area of ​​the cutting edge.

[0009] The ultrasonic vibration module is connected to the handle of the composite tool;

[0010] The power supply module provides power to the magnetic field generating module and the ultrasonic vibration module;

[0011] The control system controls the ultrasonic vibration module and the power supply module.

[0012] As a further technical solution, the power supply module is a non-contact inductive power supply module, and the excitation coil is powered by the non-contact inductive power supply module.

[0013] As a further technical solution, a machine tool is also included, which includes a machine tool spindle and a worktable for clamping workpieces and providing main motion and feed motion.

[0014] As a further technical solution, the non-contact inductive power supply module includes a stator coil, which is disposed outside the machine tool spindle, and energy is transferred between the stator coil and the excitation coil through high-frequency electromagnetic coupling.

[0015] As a further technical solution, the composite tool is also provided with a cooling channel inside and connected to an external cooling system for forced cooling of the excitation coil to ensure the stability of the magnetic field generating module under continuous working conditions.

[0016] As a further technical solution, the magnetic end of the magnetic conductor is shaped as a wedge, a needle tip, or a multi-pole array structure to form a high gradient magnetic field with a specific spatial distribution in a local area in front of the cutting edge, which is used to achieve dynamic orientation guidance of the fibrous reinforcing phase or dynamic migration control of the granular reinforcing phase.

[0017] As a further technical solution, a monitoring and feedback module is also included. The monitoring and feedback module includes a cutting force sensor and an infrared temperature monitoring unit, which are used to collect cutting force signals and temperature field information during the processing, respectively, and feed them back to the control system to form a closed-loop control system, so as to realize online adaptive optimization and adjustment of magnetic field parameters and ultrasonic vibration parameters.

[0018] As a further technical solution, the magnetic field generated by the magnetic field generating module is a steady-state magnetic field or a time-varying magnetic field that is synchronously modulated with the cutting cycle. Its magnetic field strength, gradient and direction can be programmed and controlled according to the magnetic properties, morphology and volume fraction of the reinforcing phase.

[0019] As a further technical solution, the vibration generated by the ultrasonic vibration module driving the composite tool is axial vibration, radial vibration, or longitudinal-torsional combined vibration.

[0020] Secondly, the present invention provides a processing method for a magnetically guided ultrasonic processing device for magnetically responsive phase composite materials, as follows:

[0021] Before the tool cuts into the material, the control system activates the magnetic field generating module, which in turn passes current through the excitation coil to generate and maintain a high-intensity, high-gradient directional controllable magnetic field in the working area of ​​the tool's cutting edge and its adjacent area. This causes the magnetic or magnetizable reinforcing phase contained in the workpiece's cutting layer material to deflect, rotate, or migrate under the action of magnetization force and gradient force. In this way, the instantaneous distribution and spatial orientation of the reinforcing phase in the material layer to be removed are dynamically optimized during the cutting process, reducing its hindering effect on the tool's cutting motion.

[0022] Simultaneously with the magnetic field dynamic guidance step, the ultrasonic vibration module is activated to drive the tool to generate high-frequency, low-amplitude vibrations along the axial, radial, or a combination of both directions. Combined with the main motion and feed motion of the machine tool, the material layer under the dynamic guidance of the magnetic field is cut to achieve efficient material removal.

[0023] This invention transforms passive response into active dynamic control throughout the entire process through a synergistic mechanism of "magnetic field guidance and vibration shearing," fundamentally reducing cutting resistance and damage, and significantly improving the processing quality, efficiency, and tool life of composite materials containing magnetic reinforcing phases.

[0024] This invention, through the deep integration of dynamic magnetic field guidance and ultrasonic vibration cutting, improves the machinability of composite materials while achieving proactive control over machining damage and tool wear throughout the entire process. Compared with existing magnetic field-assisted machining methods,

[0025] The present invention has the following beneficial effects:

[0026] 1. Real-time dynamic guidance of the magnetic reinforcing phase (such as fibers and particles) inside the composite material is achieved in the cutting edge region. The spatial distribution and orientation of the reinforcing phase are transformed from a random and disordered state to a controlled state that is conducive to removal (such as fibers turning to an easily shearable direction and particles deviating from the tool path), reducing the impact and obstruction of the reinforcing phase on the tool and solving the problem that existing technologies cannot intervene in the microstructure of the material and have randomness in material removal.

[0027] 2. Coupling of microscopic magnetic field guidance with macroscopic ultrasonic vibration shearing. Magnetic field guidance creates a stable and ideal microscopic environment, while ultrasonic vibration reduces cutting forces and interfacial impact strength. The synergistic effect suppresses large fluctuations in cutting forces caused by the random distribution of reinforcing phases, avoids machining damage, and improves the surface integrity of the workpiece.

[0028] 3. It has the ability to adapt to different materials. By synergistically adjusting the magnetic field parameters (intensity, direction, and gradient) and ultrasonic parameters (frequency and amplitude), it can match reinforcing phases with different magnetic properties, morphologies, and contents, thus broadening the scope of application of the process and solving the bottleneck of poor adaptability of existing technologies to material changes.

[0029] 4. By guiding the reinforcing phase to avoid the tool path at the microscopic level, the direct contact, friction, and impact between the hard reinforcing phase and the tool edge are reduced, thus slowing down the tool wear rate and extending tool life. This ensures machining quality while improving machining efficiency, solving the pain points of high tool wear and high cost in traditional machining and existing magnetically assisted machining. Attached Figure Description

[0030] Figure 1 This is a schematic diagram of the overall structure of the processing device disclosed in Embodiments 1 and 2 of the present invention.

[0031] Figure 2 This is a partial cross-sectional schematic diagram of the composite cutting tool disclosed in Embodiments 1 and 2 of the present invention.

[0032] Figure 3 This is a schematic diagram of the initial state of random fiber distribution disclosed in Example 1.

[0033] Figure 4 This is a schematic diagram of the fiber magneto-ordered arrangement structure disclosed in Example 1.

[0034] Figure 5This is a schematic diagram of the fiber magnetostriction-vibration shearing process disclosed in Example 1.

[0035] Figure 6 This is a schematic diagram of the initial state of random particle distribution disclosed in Example 2.

[0036] Figure 7 This is a schematic diagram of the particle vibration shearing process disclosed in Example 2.

[0037] Figure 8 This is a schematic diagram of the particle magnetostrictive migration distribution-vibration shearing process disclosed in Example 2.

[0038] Figure 9 This is a schematic diagram of the non-contact inductive power supply module of the processing apparatus disclosed in Embodiments 1 and 2.

[0039] Among them, 1. Control system, 2. Ultrasonic generator, 3. Transducer, 4. Amplitude bar, 5. Worktable, 6. Machine tool spindle, 7. Composite tool, 71. Excitation coil, 72. Magnetic conductor, 73. Cooling channel, 8. Infrared monitoring camera, 9. Workpiece, 91. Magnetic fiber, 92. Magnetic particles, 93. Matrix, 94. Debris, 10. Cutting force sensor, 11. Stator coil. Detailed Implementation

[0040] It should be noted that the following detailed description is illustrative and intended to provide further explanation of the invention. Unless otherwise specified, all technical and scientific terms used in this invention have the same meaning as commonly understood by one of ordinary skill in the art to which the invention pertains.

[0041] It should be noted that the terminology used herein is for the purpose of describing particular embodiments only and is not intended to limit the scope of exemplary embodiments according to the invention. As used herein, unless otherwise expressly indicated by the invention, the singular form is also intended to include the plural form. Furthermore, it should be understood that when the terms "comprising" and / or "including" are used in this specification, they indicate the presence of features, steps, operations, devices, components, and / or combinations thereof.

[0042] For ease of description, the words "up," "down," "left," and "right" appearing in this invention only indicate that they are consistent with the up, down, left, and right directions of the accompanying drawings themselves, and do not limit the structure. They are merely for the purpose of facilitating the description of this invention and simplifying the description, and do not indicate or imply that the device or component 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 this invention.

[0043] As described in the background section, existing technologies have shortcomings. To address these technical problems, this invention proposes a magnetic field-guided ultrasonic machining method and apparatus for magnetically responsive composite materials. By actively regulating the microscopic distribution of the reinforcing phase within the workpiece material using a magnetic field, the state of the reinforcing phase is precisely optimized "before" the shearing action occurs between the tool and the material. This creates a favorable cutting environment for the tool, fundamentally reducing cutting resistance and machining damage, thus overcoming the technical bottleneck of high-quality and efficient machining of composite materials containing magnetic or magnetizable reinforcing phases. This invention differs from simply using a magnetic field as an external means to improve the machining environment. It utilizes the coupling effect of pulsed electric fields, pulsed magnetic fields, and ultrasonic vibration to assist machining, deeply integrating the magnetic field into the intrinsic regulation of the material's microstructure. By integrating a magnetic conductor capable of generating a high-gradient magnetic field inside the tool, real-time and dynamic "guiding" and "migration" control of the magnetic reinforcing phase (such as fibers and particles) in the composite material is achieved for the first time in the working area of ​​the cutting edge. By optimizing the instantaneous state of the reinforcing phase on the cutting path at the microscale using magnetic force (such as orienting fibers towards a shearable direction and causing particles to deviate from the tool path), cutting resistance and damage risk are reduced from the source. Based on this, ultrasonic vibration shearing is coupled to achieve a synergistic effect of "microstructure control" and "low-force, high-efficiency removal". This can significantly improve chip breaking and chip removal performance, reduce drilling force and tool wear, extend tool life, and solve the microstructure control problem that existing magnetic-assisted technology cannot address.

[0044] Example 1

[0045] This embodiment provides a composite material processing device based on magnetic field guidance and ultrasonic shearing, mainly including a machine tool body, an ultrasonic vibration module, a magnetic field generating module, a composite cutting tool 7, a non-contact inductive power supply module, and a control system 1.

[0046] The object to be processed is workpiece 9. In this embodiment, workpiece 9 is a ferromagnetic stainless steel fiber aluminum alloy matrix composite material.

[0047] The main body of the machine tool includes a machine tool spindle 6 and a worktable 5, which are used to clamp the workpiece 9 and provide main motion and feed motion;

[0048] The composite tool 7 is mounted on the machine tool spindle 6 and connected to the ultrasonic vibration module; the magnetic field generating module is integrated inside the composite tool 7; the control system 1 is electrically connected to the machine tool body, the ultrasonic vibration module and the magnetic field generating module respectively, and is used to realize the coordinated control of magnetic field application, ultrasonic vibration and machine tool movement, so that the workpiece 9 can simultaneously receive magnetic field guidance and ultrasonic vibration assisted cutting during the processing.

[0049] Specifically, the ultrasonic vibration module includes an ultrasonic generator 2, a transducer 3, and an amplitude transformer 4, which are used to convert high-frequency electrical signals into high-frequency mechanical vibrations of the composite tool 7.

[0050] The magnetic field generating module includes at least one set of excitation coils 71 and a magnetic conductor 72 made of a high-permeability material. The excitation coils 71 are wound inside the composite tool 7, and the magnetic conductor 72 is embedded in the front end of the tool and close to the cutting edge area to generate a high-intensity, high-gradient directional controllable magnetic field in the working area of ​​the cutting edge. The excitation coils 71 are connected to an external power supply through a non-contact inductive power supply module located inside or at the end of the machine tool spindle 6. The non-contact inductive power supply module includes a stator coil 11, an excitation coil 71, and a control system 1. The stator coil 11 and the excitation coil 71 transmit electrical energy through electromagnetic coupling, thereby providing a stable and controllable working current to the excitation coil 71 when the tool is rotating at high speed.

[0051] The composite tool 7 has an internal cavity machined inside the tool holder, the excitation coil 71 is disposed in the internal cavity, and the magnetic end of the magnetic conductor 72 is precision machined and extends to a position close to the cutting edge.

[0052] Furthermore, the magnetic end portion of the magnetic conductor 72 is shaped as a wedge, a needle tip, or a multi-pole array structure to form a high gradient magnetic field with a specific spatial distribution in a local area in front of the cutting edge, which is used to achieve dynamic orientation guidance of the fibrous reinforcing phase or dynamic migration control of the granular reinforcing phase.

[0053] Furthermore, the excitation coil 71 is powered by non-contact induction, and a stator coil 11 is provided outside the machine tool spindle 6. Energy is transferred between the excitation coil 71 and the stator coil 11 through high-frequency electromagnetic coupling.

[0054] Specifically, such as Figure 2 As shown, the composite tool 7 uses a cemented carbide body with an axially machined cavity inside. An excitation coil 71 is wound within this cavity, and the excitation coil 71 is made of high-temperature resistant insulated wire. Near the cutting edge, the composite tool 7 has a magnetic conductor 72 made of a high-saturation magnetic density soft magnetic material embedded in its front end. The magnetic conductor 72 is designed as a wedge-shaped magnetic pole with sharp ends, symmetrically arranged near the flank face of the main cutting edge, with its tip close to the cutting edge. When a direct current or a specific waveform current is applied to the excitation coil 71, a high-intensity, high-gradient directional magnetic field is formed between the wedge-shaped magnetic poles and in front of them. The direction of the magnetic field is approximately parallel to the flank face of the tool and points towards the interior of the workpiece.

[0055] Furthermore, the composite tool 7 is equipped with a cooling channel 73 inside, which is connected to the machine tool cooling system to force cooling of the excitation coil 71, so as to ensure the stability of the magnetic field generating module under continuous working conditions.

[0056] In this embodiment, the excitation coil 71 is powered by a non-contact inductive power supply module located at the end of the machine tool spindle 6. The stator coil 11 is fixed to the spindle housing, and the excitation coil 71 is coaxially mounted with the tool shank. When high-frequency AC current is applied to the stator coil 11, a current is induced in the excitation coil 71, thereby achieving reliable power supply to the magnetic field generation module under high-speed tool rotation.

[0057] Furthermore, the control system 1 is configured to execute the following collaborative control strategy: drive the magnetic field generating module to work during the processing, so that the cutting area is under the action of the magnetic field; and dynamically adjust the magnetic field strength, direction and gradient according to preset process parameters or real-time feedback signals to realize the whole process of adaptive guidance for the enhancement phase space distribution and orientation; and simultaneously control the vibration parameters of the ultrasonic vibration module and the motion parameters of the machine tool body.

[0058] Furthermore, it also includes a monitoring and feedback module, which includes a cutting force sensor 10 and an infrared monitoring camera 8, used to collect cutting force signals and temperature field information during the machining process, and feed them back to the control system 1 to form a closed-loop control system 1, so as to realize online adaptive optimization adjustment of magnetic field parameters and ultrasonic vibration parameters.

[0059] Furthermore, the magnetic field generated by the magnetic field generating module is a steady-state magnetic field or a time-varying magnetic field that is synchronously modulated with the cutting cycle. Its magnetic field strength, gradient, and direction can be programmed and controlled according to the magnetic properties, morphology, and volume fraction of the reinforcing phase.

[0060] Furthermore, the vibration generated by the composite cutter 7 driven by the ultrasonic vibration module is axial vibration, radial vibration, or longitudinal-torsional composite vibration, with a vibration frequency range of 20 kHz to 40 kHz and an amplitude range of 1 μm to 10 μm.

[0061] This embodiment also provides a composite material processing method based on magnetic field guidance and ultrasonic shearing, and the technical solution adopted is as follows:

[0062] 1) Dynamic Magnetic Field Guidance: Throughout the cutting process of the composite tool 7 on the workpiece 9, the magnetic field generating module is activated to generate a high-intensity, high-gradient, directional, and controllable magnetic field in the working area of ​​the cutting edge of the composite tool 7 and its adjacent area. This magnetic field acts on the magnetic or magnetizable reinforcing phase contained in the cutting layer material of the workpiece 9, causing it to dynamically deflect, rotate, or migrate microscopically during the cutting process through magnetization force and gradient force. This optimizes the instantaneous distribution and spatial orientation of the reinforcing phase in the material layer to be removed in real time at the microscale, reducing its real-time resistance to the cutting motion of the tool.

[0063] 2) Vibration shearing: While the magnetic field dynamic guidance step is being performed, the ultrasonic vibration module is activated to drive the composite tool 7 to vibrate at high frequency and low amplitude along its axial, radial or combined direction. Combined with the main motion and feed motion of the machine tool, the material layer under the dynamic guidance of the magnetic field is cut to remove the material.

[0064] Furthermore, since the workpiece 9 in this embodiment is a magnetic fiber 91 reinforcing phase, by controlling the direction of the magnetic field, the long axis of the fiber is subjected to magnetic moment during the cutting process and its orientation is dynamically adjusted. Ultimately, it is made to be nearly perpendicular to the cutting edge of the tool or at a large angle at the moment of shearing, so that it is in the state most easily sheared and cut off, thus avoiding the fiber being "pried" parallel to the cutting edge or root, which would cause the matrix 93 to tear.

[0065] For details, see Figure 1 and Figures 3-5 The processing method in this embodiment specifically includes the following steps:

[0066] 1) Clamping and tool setting

[0067] The workpiece 9 is clamped on the fixture of the worktable 5, and the composite tool 7 is installed on the machine tool spindle 6 to complete the tool setting operation.

[0068] 2) Processing parameter settings

[0069] Input machining parameters into the computer control system 1, including spindle speed S, feed rate F, and depth of cut ap; set ultrasonic vibration parameters as frequency f=28 kHz and amplitude A=5 μm (axial vibration); set magnetic field parameters as excitation coil 71 with working current I=10 A, and why is there a lower horizontal bar corresponding to the generation of a sharp magnetic field of about 0.8 T in the cutting edge area, the direction of the magnetic field is maintained or finely adjusted according to the requirements of the machining area.

[0070] 3) Combined processing of magnetic field guidance and ultrasonic vibration shearing

[0071] After the machine tool starts, before the composite tool 7 cuts into the material, the control system 1 activates the magnetic field generating module, causing current to flow through the excitation coil 71 to establish a stable magnetic field environment in the cutting edge region. When the composite tool 7 enters the material, as... Figures 3-5 As shown, under the influence of a strong magnetic field, the magnetic moments of the magnetic fiber 91 tend to align along the direction of the magnetic field lines, causing the long axis of the fiber to dynamically deflect and adjust its orientation before and during the cutting process. In this embodiment, the magnetic field direction is set to make the fiber tend to be perpendicular to the main cutting direction, thereby facilitating the shearing and cutting of the fiber by the tool.

[0072] Simultaneously, the ultrasonic vibration module is activated, causing the composite tool 7 to generate high-frequency axial vibration. During rotation and feed, the vibrating cutting edge of the tool cuts into the material layer under the dynamic guidance of the magnetic field. Since the fibers are already in a favorable orientation at the moment of cutting, the energy required for fiber breakage is significantly reduced, the cutting force is significantly reduced and more stable, and the intermittent cutting effect generated by ultrasonic vibration further reduces the cutting force and cutting heat. The magnetic field acts continuously throughout the cutting process, not only pre-treating the material to be cut, but also guiding the forming chips and the reinforcing phase near the newly machined surface, thereby optimizing the microstructure of the entire cutting zone.

[0073] 4) Monitoring and Adaptive Control

[0074] The cutting force sensor 10 monitors the three-dimensional cutting force signal in real time, and the infrared monitoring camera 8 monitors the temperature field distribution in the machining area in real time and feeds the data back to the control system 1. When an abnormal increase in cutting force is detected, the control system 1 can determine that the local fiber content has increased or the magnetic field guidance effect is insufficient, and automatically increase the excitation current I or adjust the ultrasonic amplitude A to achieve closed-loop optimization control of the machining process.

[0075] Example 2

[0076] This embodiment provides a processing method for composite materials containing magnetic particle 92 reinforcing phase (such as iron powder particles), see [link to relevant documentation]. Figures 6-8 The same processing apparatus as disclosed in Example 1 is used; however, for the magnetic particle 92 reinforcing phase, the apparatus designs a gradient distribution of the magnetic field to form a specific magnetic field environment (such as a gradient-increasing repulsive field) in front of the cutting edge, and applies a gradient force to the magnetic particles 92 pointing to both sides or the rear of the tool movement direction, causing them to continuously undergo microscopic migration during the cutting process, thereby dynamically "clearing" the direct movement path of the cutting edge, which is equivalent to dynamically "clearing obstacles" on the cutting path.

[0077] Specifically, such as Figure 6 As shown, in the initial state, magnetic particles 92 are randomly distributed in the matrix 93; as Figure 7 As shown, under normal vibration cutting conditions, magnetic particles 92 easily come into direct contact with the cutting tool and cause wear; for example Figure 8 As shown, after applying a gradient magnetic field, the magnetic particles 92 migrate to both sides in the cutting area due to the gradient force of the magnetic field, forming a sparse "cutting channel" in front of the tool. This reduces the impact and wear of the particles on the tool, improving machining quality and tool life. The debris 94 in the figure are small debris generated during the machining of workpiece 9.

[0078] In summary, this invention achieves dynamic micro-control of the machining process of magnetically reinforced composite materials through the synergistic coupling of magnetic field and ultrasonic vibration in time and space. This effectively reduces cutting force and cutting heat, improves machining quality, and extends tool life, providing a new technical solution for the efficient and low-damage machining of such difficult-to-machine materials.

[0079] Finally, it should be noted that relational terms such as first and second are used only to distinguish one entity or operation from another, and do not necessarily require or imply any such actual relationship or order between these entities or operations.

[0080] The above description is merely a preferred embodiment of the present invention and is not intended to limit the invention in any other way. Any person skilled in the art may make changes or modifications to the above-disclosed technical content to create equivalent embodiments. However, any simple modifications, equivalent changes, and modifications made to the above embodiments based on the technical essence of the present invention without departing from the scope of the present invention shall still fall within the protection scope of the present invention.

Claims

1. A processing method for a magnetically guided ultrasonic processing device for magnetically responsive phase composite materials, characterized in that, A magnetic field-guided ultrasonic machining device, including a magnetically responsive phase composite material, comprises an ultrasonic vibration module, a magnetic field generating module, a composite cutting tool, a power supply module, and a control system; The composite cutting tool has an internal cavity; The magnetic field generating module is located inside the cavity and includes at least one set of excitation coils and a magnetic conductor. Some of the excitation coils are wound around the magnetic conductor. The magnetic conductor is embedded in the front end of the tool and close to the cutting edge area to generate a directional and controllable magnetic field with a set intensity and gradient in the working area of ​​the cutting edge. The ultrasonic vibration module is connected to the handle of the composite tool; The power supply module provides power to the magnetic field generating module and the ultrasonic vibration module; The control system controls the ultrasonic vibration module and the power supply module; The composite tool has an internal cavity machined inside the tool holder, the excitation coil is disposed in the internal cavity, and the magnetic extreme end of the magnetic conductor is precision machined and extends to a position close to the cutting edge; The control system is configured to execute the following collaborative control strategy: drive the magnetic field generating module to work during the machining process, so that the cutting area is under the action of the magnetic field; and dynamically adjust the magnetic field strength, direction and gradient according to preset process parameters or real-time feedback signals to adaptively guide the entire process of enhancing phase space distribution and orientation; and simultaneously control the vibration parameters of the ultrasonic vibration module and the motion parameters of the machine tool body. The device also includes a monitoring and feedback module, which includes a cutting force sensor and an infrared temperature monitoring unit, used to collect cutting force signals and temperature field information during the machining process, respectively, and feed them back to the control system to form a closed-loop control system, thereby realizing online adaptive optimization adjustment of magnetic field parameters and ultrasonic vibration parameters. Before the tool cuts into the material, the control system activates the magnetic field generating module, which in turn passes current through the excitation coil to generate and maintain a high-intensity, high-gradient directional controllable magnetic field in the working area of ​​the tool's cutting edge and its adjacent area. This causes the magnetic or magnetizable reinforcing phase contained in the workpiece's cutting layer material to deflect, rotate, or migrate under the action of magnetization force and gradient force. In this way, the instantaneous distribution and spatial orientation of the reinforcing phase in the material layer to be removed are dynamically optimized during the cutting process, reducing its hindering effect on the tool's cutting motion. Simultaneously with the magnetic field dynamic guidance step, the ultrasonic vibration module is activated to drive the tool to generate high-frequency, low-amplitude vibrations along the axial, radial, or a combination of both directions. Combined with the main motion and feed motion of the machine tool, the material layer under the dynamic guidance of the magnetic field is cut to achieve efficient material removal.

2. The processing method of the magnetic field-guided ultrasonic processing device for magnetically responsive phase composite materials as described in claim 1, characterized in that, The power supply module is a non-contact inductive power supply module, and the excitation coil is powered by the non-contact inductive power supply module.

3. The processing method of the magnetic field-guided ultrasonic processing device for magnetically responsive phase composite materials as described in claim 2, characterized in that, The non-contact inductive power supply module includes a stator coil and a control system, wherein the stator coil is located outside the machine tool spindle.

4. The processing method of the magnetic field-guided ultrasonic processing device for magnetically responsive phase composite materials as described in claim 1, characterized in that, The device also includes a machine tool, which includes a machine tool spindle and a worktable for clamping workpieces and providing main motion and feed motion.

5. The processing method of the magnetic field-guided ultrasonic processing device for magnetically responsive phase composite materials as described in claim 1, characterized in that, The composite tool also has internal cooling channels and is connected to an external cooling system.

6. The processing method of the magnetic field-guided ultrasonic processing device for magnetically responsive phase composite materials as described in claim 1, characterized in that, The magnetic end of the magnetic conductor is wedge-shaped, needle-shaped, or a multi-pole array structure.

7. The processing method of the magnetic field-guided ultrasonic processing device for magnetically responsive phase composite materials as described in claim 1, characterized in that, The magnetic field generated by the magnetic field generating module is a steady-state magnetic field or a time-varying magnetic field that is synchronously modulated with the cutting cycle. Its magnetic field strength, gradient and direction can be programmed and controlled according to the magnetic properties, morphology and volume fraction of the reinforcing phase.

8. The processing method of the magnetic field-guided ultrasonic processing device for magnetically responsive phase composite materials as described in claim 1, characterized in that, The ultrasonic vibration module drives the composite tool to generate vibrations in the form of axial vibration, radial vibration, or a combination of longitudinal and torsional vibration.

Images