Automobile part cutting equipment

Abstract

The invention relates to the technical field of automobile part machining, in particular to automobile part cutting equipment which comprises a machine body with a cutter arranged on the front side, two sets of limiting adjusting parts and two sets of cutting devices, the cutter performs periodic reciprocating rotation of 0-120 degrees around a tubular turbocharger shell made of high-silicon nodular cast iron and Ni-Resist cast iron, and the two sets of limiting adjusting parts are arranged on the machine body. The two limiting adjusting parts are symmetrically distributed on the left and right sides of the machine body. The micro-fluid annular channel filled with high-viscosity silicone oil is arranged in the lifting sliding block, the micro-fluid annular channel is matched with the hot wire type flow velocity sensor and the piezoelectric film sensor which are evenly distributed in the circumferential direction, the eccentric vibration state of the bearing rotating shaft is sensed in real time, and the ultrasonic vibration assistor is arranged and matched with a precise transmission structure of the piezoelectric ceramic transducer and the amplitude-change pole at the same time. The ultrasonic vibration system is ensured to always work in the optimal resonance state, the tool wear rate is greatly reduced, and the problem that high-hardness heat-resistant material cutting is difficult to deal with in the prior art is avoided.

Description

Technical Field

[0001] This invention relates to the field of automotive parts processing technology, and in particular to an automotive parts cutting device. Background Technology

[0002] The turbocharger housing is a core component of an automotive turbocharger system. It directly withstands the high-temperature exhaust gases from the engine and must be manufactured from heat-resistant and wear-resistant materials such as high-silicon ductile iron, Ni-Resist cast iron, or heat-resistant cast steel. The turbocharger housing has an irregular, thin-walled structure, making it extremely difficult to machine.

[0003] Under current conditions, the machining of turbine housings mainly relies on CNC lathes in conjunction with conventional turning tools. For example, a milling device for automotive parts disclosed in CN210877571U eliminates friction noise and assists in tool heat dissipation through sound-absorbing holes, extending tool life. Another example is a turning equipment for automotive parts disclosed in CN117161419B, which provides effective support for turning drive shafts by using support frames on both sides of a sliding seat to drive a pallet and rollers. However, when applied to the machining of tubular turbocharger housings made of high-silicon ductile iron and Ni-Resist cast iron, the following shortcomings still exist: Firstly, high-silicon ductile iron and Ni-Resist cast iron have high hardness, resulting in extremely severe tool wear during machining. In conventional turning, the cutting edge becomes dull rapidly, leading to a rapid deterioration of surface roughness and requiring frequent machine stops for tool changes, severely limiting machining efficiency. While existing technologies propose using sound-absorbing holes to assist heat dissipation and extend tool life, this solution only addresses heat dissipation and fails to effectively reduce the cutting force itself, thus having limited effectiveness in cutting high-hardness materials.

[0004] Secondly, the turbocharger housing has a thin-walled structure and an irregular shape, resulting in poor rigidity and insufficient clamping stability, which easily leads to chatter during traditional turning processes. Existing technologies use passive support structures, which can provide some mechanical support, but cannot actively sense and suppress the dynamic vibrations generated during cutting. The chatter problem remains prominent, causing vibration marks on the machined surface and affecting sealing performance and fatigue life.

[0005] Third, the cutting parameters of existing cutting equipment mainly rely on operational experience for setting, lacking the ability to monitor and adaptively adjust tool wear and cutting conditions in real time, making it difficult to maximize workpiece output while ensuring machining accuracy. Summary of the Invention

[0006] The purpose of this invention is to solve the problem of low machining quality caused by the difficulty in machining turbocharger housings in the prior art, and to propose a machining equipment for automotive parts.

[0007] To achieve the above objectives, the present invention adopts the following technical solution: A cutting device for automotive parts includes a body with a cutter positioned at the front, the cutter reciprocating periodically from 0° to 120° around a tubular turbocharger housing made of high-silicon ductile iron and Ni-Resist cast iron, and further includes: Two sets of limit adjustment parts are symmetrically distributed on the left and right sides of the machine body. Each set includes a lifting slider, a load-bearing rotating shaft, and at least two sets of locking clamps. The lifting slider is provided with a biomimetic adaptive bearing for maintaining the load-bearing rotating shaft in a centered position. The locking clamps include a silicone outward expansion plate and a wear-resistant clamping plate. The silicone outward expansion plate expands from the inside to the outside to support the tubular turbocharger housing port, and the wear-resistant clamping plate closes from the outside to the inside to clamp the tubular turbocharger housing port. The cooling and lubrication unit is movably located at the rear of the machine body. It includes a supply tank and an amplitude adjustment plate connected by a corrugated hose. The amplitude adjustment plate is provided with a booster nozzle for spraying cooling and lubricating agent onto the cutting part of the tubular turbocharger housing according to the cutting tool. The lubricant includes water-based coolant and vegetable oil-based lubricant. The booster nozzle includes a first nozzle that sprays water-based coolant in the form of water droplets and a second nozzle that sprays vegetable oil-based lubricant in the form of aerosol.

[0008] Preferably, the limiting adjustment part further includes a movable support frame, which is slidably mounted on the machine body in a left-right direction, and the lifting slider is slidably mounted on the movable support frame in a longitudinal direction.

[0009] Preferably, the biomimetic adaptive bearing includes a microfluidic annular channel formed in the lifting slider and filled with high-viscosity silicone oil. Multiple circumferentially equidistant flow velocity sensors are fixedly arranged on the outer side of the inner wall of the microfluidic annular channel, and a piezoelectric ceramic stack actuator connected to the flow velocity sensors is fixedly arranged on the inner side of the inner wall of the microfluidic annular channel. An arc petal for forming a floating inner support ring around the load-bearing shaft is fixedly connected to the output end of the piezoelectric ceramic stack actuator. A piezoelectric thin film sensor is attached to the inner surface of the arc petal. A microcontroller and a power amplifier connected to the flow velocity sensor and the piezoelectric thin film sensor are arranged on the lifting slider.

[0010] Preferably, the flow sensor is a hot-wire flow sensor, which is used to detect the annular flow of high-viscosity silicone oil fluid caused by shaft vibration.

[0011] Preferably, the number of the piezoelectric ceramic stacked actuators is 4-12, and they are equidistantly distributed in the circumferential direction.

[0012] Preferably, a load-bearing disc is integrally connected to the load-bearing shaft, and an elastic guide sleeve with a movable silicone outer expansion plate is slidably installed on the load-bearing disc. A synchronous chain connects the elastic guide sleeve and the wear-resistant clamping plate.

[0013] Preferably, the arc lobe is in active contact with the outer surface of the load-bearing rotating shaft through a piezoelectric ceramic stack actuator, and the arc lobe is radially displaced by the piezoelectric ceramic stack actuator under applied voltage.

[0014] Preferably, a steering sprocket that meshes with a synchronous chain is rotatably mounted on the load plate, and the synchronous chain has a U-shaped structure through the steering sprocket.

[0015] Preferably, the cooling and lubrication section further includes a first three-dimensional moving bracket movably disposed on the machine body, on which a self-locking slider for rotating and mounting an amplitude adjustment plate is movably mounted.

[0016] Preferably, the machine body is further provided with an ultrasonic vibration auxiliary device for driving the cutter to perform cutting operations around the tubular turbocharger housing. The ultrasonic vibration auxiliary device includes a second three-dimensional moving bracket movably mounted on the machine body. A guide semi-ring is provided on the second three-dimensional moving bracket. A telescopic semi-ring is slidably fitted in the guide semi-ring. A piezoelectric ceramic transducer is fixedly mounted on the telescopic semi-ring, and an amplitude transformer rod connected to the output end of the piezoelectric ceramic transducer and used to fix the cutter is movably mounted on the telescopic semi-ring.

[0017] Compared with the prior art, the present invention has the following advantages: 1. This invention sets up a microfluidic annular channel filled with high-viscosity silicone oil in the lifting slider, and uses a circumferentially distributed hot wire flow velocity sensor and piezoelectric thin film sensor to sense the eccentric vibration state of the load-bearing shaft in real time. The microcontroller drives the piezoelectric ceramic stacked actuator to adjust the radial displacement of the arc lobe, forming a floating inner support ring to actively counteract the eccentric vibration, achieving millisecond-level active shaft stabilization control, effectively suppressing the cutting chatter of the thin-walled structure of the turbine housing during the cutting process, thereby improving the surface quality of the machined surface.

[0018] 2. This invention, by setting an ultrasonic vibration auxiliary device, enables the cutter to generate high-frequency micro-amplitude vibrations of 20~40kHz and 5~30μm, forming periodic separation and contact between the cutting tool and the workpiece material. The average cutting force can be effectively reduced compared with traditional continuous cutting. At the same time, with the precision transmission structure of the piezoelectric ceramic transducer and the amplitude transformer, it is ensured that the ultrasonic vibration system always works in the optimal resonance state, and the tool wear rate is greatly reduced, avoiding the problem that existing technologies cannot handle the cutting of high-hardness heat-resistant materials.

[0019] 3. This invention achieves synchronized action of the silicone outer expansion support plate expanding from the inside out and the wear-resistant clamping plate closing and clamping from the outside in through a linkage mechanism consisting of a drive slider, traction link, elastic guide sleeve, synchronous chain and steering sprocket. This forms radial centering and axial locking of the tubular turbocharger housing port in a coordinated manner. Compared with the single-sided clamping method that relies solely on the rotating sleeve and clamping components, this helps to improve the clamping rigidity and positioning accuracy of the thin-walled turbine housing and avoids processing errors caused by unstable clamping.

[0020] 4. This invention receives feedback signals from the flow rate sensor and the piezoelectric thin film sensor in real time through a microcontroller, dynamically adjusts the frequency and amplitude of ultrasonic vibration and the voltage of the piezoelectric ceramic stack actuator, and can reduce the feed rate when necessary, forming a closed-loop adaptive control system of perception-decision-execution. This breaks through the limitations of existing technologies that rely on operational experience to set cutting parameters, and helps to realize intelligent control of the cutting process, improving the stability and controllability of machining accuracy. Attached Figure Description

[0021] Figure 1 This is a schematic diagram of the structure of an automotive parts cutting device proposed in this invention; Figure 2 This is a bottom view of an automotive parts cutting device proposed in this invention; Figure 3 This is a schematic diagram of the limit adjustment part of an automotive parts cutting equipment proposed in this invention; Figure 4 This is a cross-sectional view of the limit adjustment part of an automotive parts cutting equipment proposed in this invention; Figure 5 This is a cross-sectional view of a biomimetic adaptive bearing structure for an automotive parts cutting equipment proposed in this invention. Figure 6 This is a schematic diagram of a locking clamp structure for an automotive parts cutting equipment proposed in this invention; Figure 7 This is a schematic diagram of the cooling and lubrication section of an automotive parts cutting equipment proposed in this invention; Figure 8 This is a cross-sectional view of the cooling and lubrication section of an automotive parts cutting equipment proposed in this invention; Figure 9 This is a schematic diagram of an ultrasonic vibration auxiliary device for automotive parts cutting equipment proposed in this invention; Figure 10 This is a cross-sectional view of the ultrasonic vibration auxiliary device structure of an automotive parts cutting equipment proposed in this invention.

[0022] In the diagram: 1. Body; 2. Limit adjustment unit; 21. Moving support frame; 22. Traction swing arm; 23. Lifting slider; 24. Traction rod; 25. Load-bearing rotating shaft; 26. Bionic adaptive bearing; 261. Microfluidic annular channel; 262. Flow velocity sensor; 263. Piezoelectric ceramic stacked actuator; 264. Arc lobe; 265. Piezoelectric thin film sensor; 266. Microcontroller; 267. Power amplifier; 27. Loading plate; 28. Drive slider; 29. ​​Locking clamp; 291. Double-layer guide elongated hole; 292. Elastic guide sleeve; 293. Wear-resistant clamping plate; 294. Traction link. 295. Steering sprocket; 296. Synchronous chain; 297. Silicone outer expansion plate; 298. Limiting linkage; 3. Cooling and lubrication section; 31. Supply tank; 32. First three-dimensional moving support; 33. Self-locking slider; 34. Driven gear; 35. Amplitude adjustment plate; 36. Corrugated hose; 37. Drive gear; 38. Pressure boosting nozzle; 381. First nozzle; 382. Second nozzle; 4. Ultrasonic vibration auxiliary device; 41. Second three-dimensional moving support; 42. Guide semi-ring; 43. Telescopic semi-ring; 44. Semi-ring rack; 45. Drive gear; 46. Piezoelectric ceramic transducer; 47. Amplitude bar; 48. Cutter. Detailed Implementation

[0023] The technical solutions of the present invention will be clearly and completely described below with reference to the accompanying drawings of the embodiments of the present invention. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments.

[0024] Reference Figures 1-10 A cutting device for automotive parts includes a body 1 with a cutter 48 positioned at the front. The cutter 48 reciprocates periodically from 0° to 120° around a tubular turbocharger housing made of high-silicon ductile iron and Ni-Resist cast iron. The cutter 48 uses PCBN inserts with a rake angle γ = -8°, a clearance angle α = 10°, and a cutting edge radius of 15μm. It also includes two sets of limit adjustment sections 2, a cooling and lubrication section 3, and an ultrasonic vibration aid 4.

[0025] Furthermore, the machine body 1 adopts an integral cast iron or welded steel frame structure, with its front area being the cutting operation area and its rear area being the cooling and lubrication follow-up area. Two parallel high-precision linear guide rails are provided on the upper surface of the machine body 1 along the length direction (left and right direction) for mounting the movable support frame 21 of the limit adjustment unit 2. At the same time, a highly integrated electrical control cabinet is installed inside the machine body 1.

[0026] Two sets of limit adjustment parts 2 are symmetrically distributed on the left and right sides of the machine body 1. Each set includes a movable support frame 21, which is slidably mounted on the machine body 1 in a left-right direction. The movable support frame 21 is driven by a servo motor combined with a ball screw pair. Both ends of the screw are supported by angular contact ball bearings, but synchronization is achieved through a CNC system to ensure that the coaxiality error of the load-bearing rotating shafts 25 on both sides does not exceed 0.02mm. A linear guide slider pair is provided at the bottom of the movable support frame 21, with a positioning accuracy of ±0.01mm, used for coarse left-right positioning. Mechanical limit blocks and photoelectric sensors are provided at both ends of the travel of the movable support frame 21 to prevent overtravel.

[0027] A traction swing arm 22 is rotatably mounted on the movable support frame 21. The traction swing arm 22 is driven by a manual or electric worm gear reducer. The self-locking characteristic of the worm gear prevents the lifting slider 23 from sliding down due to its own weight. Alternatively, a grease filling port and a sealing dust strip are provided between the lifting slider 23 and the movable support frame 21 to ensure smooth long-term operation. The longitudinally sliding lifting slider 23 is movably mounted on the movable support frame 21. A traction rod 24 is movably connected between the traction swing arm 22 and the lifting slider 23. In some embodiments, the traction swing arm 22 is connected to the traction rod 24 via a spherical bearing to achieve smooth transmission of the swing torque. The lifting slider 23 slides on the T-shaped or rectangular guide rail of the movable support frame 21, driven by the torque transmitted by the traction rod 24. The vertical stroke accuracy is determined by the rotation angle of the traction swing arm 22 and the length of the traction rod 24. A grating ruler can be added to achieve closed-loop control.

[0028] Furthermore, a load-bearing shaft 25 is rotatably mounted in the lifting slider 23. The load-bearing shaft 25 is directly driven by a spindle servo motor via a pulley or coupling, with a spindle speed range of 0~3000 r / min. A built-in encoder is used for speed closed-loop and angle positioning. A biomimetic adaptive bearing 26 is provided in the lifting slider 23 to maintain the centered rotation of the load-bearing shaft 25. A load-bearing disk 27 is integrally connected to the load-bearing shaft 25, and a drive slider 28 is slidably mounted in the load-bearing shaft 25. The drive slider 28 is axially driven by a hydraulic cylinder or electric push rod, and a displacement sensor is installed inside the cylinder to achieve proportional control of the clamping force. The drive slider 28 and the load-bearing shaft 25 are slidably connected via a rectangular spline or guide key, transmitting torque while allowing axial movement. At least two sets of locking clamps 29 are provided on the load-bearing disk 27.

[0029] In some embodiments, the biomimetic adaptive bearing 26 includes a microfluidic annular channel 261 formed within the lifting slider 23 and filled with high-viscosity silicone oil. The channel has a rectangular or circular cross-sectional shape and is machined inside the lifting slider 23. The inner wall of the channel is precision polished to reduce the frictional resistance of the high-viscosity silicone oil. Multiple circumferentially equidistant flow rate sensors 262 are fixedly disposed on the outer side of the inner wall of the microfluidic annular channel 261. For the selection of the microfluidic fluid, low-viscosity or medium-viscosity silicone oil can also be used. Low-viscosity silicone oil has the advantage of fast response speed, but it is sensitive to small vibrations and is prone to noise. It is suitable for low-speed heavy-load conditions. Medium viscosity silicone oils offer a good balance between response speed and noise reduction, making them suitable for most turbine housing machining processes; High-viscosity silicone oil has high damping properties and a slightly slower response, but it has strong anti-interference ability and is suitable for working conditions with strong external impacts.

[0030] The machining requirements of tubular turbocharger housings can be met by selecting medium viscosity silicone oil.

[0031] A piezoelectric ceramic stacked actuator 263, electrically connected to a flow velocity sensor 262, is fixedly installed on the inner wall of the microfluidic annular channel 261. Each piezoelectric ceramic stacked actuator 263 is composed of multiple layers of piezoelectric ceramic sheets, externally wrapped with an insulating and waterproof layer. An arc-shaped lobe 264, forming a floating inner support ring around the load-bearing rotating shaft 25, is fixedly connected to the output end of the piezoelectric ceramic stacked actuator 263. The number of arc-shaped lobe 264 is the same as the number of piezoelectric ceramic stacked actuators 263. Each arc-shaped lobe 264 is an arc-shaped metal block (made of high-strength aluminum alloy or stainless steel), with a polyimide insulating film attached to its inner surface. All arc-shaped lobe 264 are not directly connected end-to-end on the circumference, leaving a gap of 0.1~0.5mm to allow for independent radial movement. A piezoelectric thin film sensor 265 is attached to the inner surface of the arc lobe 264. A microcontroller 266 and a power amplifier 267 are provided on the lifting slider 23 and are electrically connected to the flow rate sensor 262 and the piezoelectric thin film sensor 265.

[0032] Furthermore, a multi-dimensional sensing network is formed by the hot-wire flow velocity sensor 262 and the piezoelectric thin film sensor 265 in the microfluidic annular channel 261. Combined with the microcontroller 266 and the power amplifier 267, 4 to 12 piezoelectric ceramic stacked actuators 263 are driven to independently control the radial displacement of the arc lobe 264, forming a floating inner support ring around the load-bearing rotating shaft 25, so as to imitate the balance adjustment mechanism of the mammalian vestibular system and achieve millisecond-level active axis stabilization.

[0033] It should be noted that the outer wall of the microfluidic annular channel 261 is also provided with an oil injection hole and an vent hole, which are used for venting and replenishing silicone oil during initial use. The sensing element of the hot wire flow sensor 262 extends into the silicone oil, and its signal line is led out to the microcontroller 266 through a sealed connector.

[0034] In some embodiments, the locking clamp 29 includes a double-layer guide elongated hole 291 opened in the load plate 27. An elastic guide sleeve 292 and a wear-resistant clamping plate 293 are movably fitted in the double-layer guide elongated hole 291. The front end of the wear-resistant clamping plate 293 is an arc-shaped claw made of hard alloy or quenched steel. The surface of the claw has a textured or serrated surface to increase the coefficient of friction. A traction link 294 is pin-connected between the elastic guide sleeve 292 and the drive slider 28. A steering sprocket 295 is rotatably mounted on the load plate 27. A synchronous chain 296 that meshes with the steering sprocket 295 is connected between the elastic guide sleeve 292 and the wear-resistant clamping plate 293. A silicone outer expansion support plate 297 is movably fitted inside the elastic guide sleeve 292. A limiting link 298 that is movably connected to the silicone outer expansion support plate 297 is pin-mounted on the load plate 27. The silicone outer expansion support plate 297 expands from the inside to the outside to support the tubular turbocharger housing port. The wear-resistant clamping plate 293 closes from the outside to the inside to clamp the tubular turbocharger housing port.

[0035] A linkage mechanism consisting of a drive slider 28, a traction link 294, an elastic guide sleeve 292, a synchronous chain 296, and a steering sprocket 295 is adopted to realize the synchronous action of the silicone outer expansion support plate 297 expanding from the inside to the outside and the wear-resistant clamping plate 293 closing and clamping from the outside to the inside.

[0036] One end of the limiting link 298 is hinged to the fixed pin on the load plate 27, and the other end is hinged to the rear end of the silicone expansion plate 297. When the elastic guide sleeve 292 moves outward, it drives the support rod of the silicone expansion plate 297 to move outward. At the same time, the limiting link 298 swings around the fixed pin, forcing the front end of the silicone expansion plate 297 to open outward, thereby tightening the inner wall of the tubular turbocharger housing.

[0037] The cooling and lubrication unit 3 is movably located at the rear of the machine body 1, including a supply tank 31 fixedly mounted on the machine body 1. The supply tank 31 has a double-layer structure, with the inner layer storing 5-20L of water-based coolant and the outer layer storing 1-5L of vegetable oil-based lubricant. A first three-dimensional moving support 32 is movably mounted on the machine body 1. The first three-dimensional moving support 32 consists of linear modules in the X, Y, and Z directions, each module being driven by a servo motor combined with a ball screw. The self-locking slider 33 has a built-in electromagnetic brake, which can maintain its position when power is off. A self-locking slider 33 with an amplitude adjustment plate 35 rotatably mounted is installed at the end of the first three-dimensional moving support 32. The amplitude adjustment plate 35, which is connected to the supply tank 31 via a corrugated hose 36, is rotatably mounted on the self-locking slider 33. A driven gear 34 is keyed to the center of the amplitude adjustment plate 35. A drive gear 37 that meshes with the driven gear 34 is rotatably mounted on the self-locking slider 33. The drive gear 37 is driven by a micro stepper motor. The drive gear 37 meshes with the driven gear 34, which is preferably a spur gear. The backlash of the gear pair can be eliminated by an eccentric adjusting sleeve. The rotation angle resolution of the amplitude adjustment plate 35 can reach 0.1°.

[0038] The amplitude adjustment plate 35 is equipped with a booster nozzle 38 that sprays cooling and lubricating agent onto the cutting part of the tubular turbocharger housing according to the cutter 48. The spray angle of the booster nozzle 38 can be adjusted in real time by the drive gear 37, with an adjustment range of ±45°. This ensures that the spray direction always forms an angle of 30° to 60° with the normal of the cutting area surface when there are different cutting directions and different curved surfaces of the tubular turbocharger housing, so as to obtain the best cooling and lubrication effect.

[0039] To further explain, the booster nozzle 38 integrates a miniature diaphragm pump or utilizes the air pressure of the supply tank 31 for boosting. The lubricant includes water-based coolant and vegetable oil-based lubricant. The booster nozzle 38 includes a first nozzle 381 that sprays water-based coolant in the form of water droplets and a second nozzle 382 that sprays vegetable oil-based lubricant in the form of aerosol. The first nozzle 381 uses centrifugal atomization of water droplets, and the second nozzle 382 uses a dual-fluid aerosol nozzle.

[0040] The first three-dimensional moving support 32 and the self-locking slider 33 drive the amplitude adjustment plate 35 to follow the position of the cutter 48 in real time, and the spray angle is precisely adjusted by the drive gear 37 and the driven gear 34. The dual media (water-based coolant droplets combined with vegetable oil-based aerosol) work together to optimize the separation of cooling and lubrication; the microcontroller 266 dynamically adjusts the ultrasonic parameters and feed speed based on the feedback from the hot wire flow sensor 262 and the piezoelectric film sensor 265, forming a closed-loop intelligent control of perception-decision-execution.

[0041] The flow velocity sensor 262 is a hot-wire flow velocity sensor, used to detect the annular flow of high-viscosity silicone oil fluid caused by shaft vibration. During the initial commissioning of the equipment, static calibration is required: the load-bearing shaft 25 is placed at its ideal center position, and the zero-point output of each flow velocity sensor 262 is measured. Then, an external vibrator is used to apply vibration of known frequency and amplitude to the load-bearing shaft 25, and the relationship curve between the output of the flow velocity sensor 262 and the vibration angular velocity is recorded to form a calibration table. In actual operation, the microcontroller 266 compares the real-time flow velocity data with the calibration table to obtain the shaft vortex angular velocity, with the error controlled within ±5%. The output of each flow velocity sensor 262 is sent to the ADC channel of the microcontroller 266 via an independent signal conditioning circuit (including a constant current source, bridge amplification, and low-pass filtering).

[0042] The number of piezoelectric ceramic stacked actuators 263 is 4-12, and they are evenly distributed circumferentially. To prevent damage to the piezoelectric ceramics due to overvoltage or reverse voltage, a bidirectional transient suppression diode and a current-limiting resistor are connected in parallel across each piezoelectric ceramic stacked actuator 263, and a current sampling resistor is connected in series in the output circuit. When the current exceeds a set threshold, the drive is immediately cut off. It is worth noting that by setting the number of piezoelectric ceramic stacked actuators 263 in various ways, different levels of stability maintenance can be achieved. 4. Actuator solution: Suitable for small turbine housings (outer diameter ≤ 80mm), circumferential interval 90°, simple control, low cost, but slightly lower calibration accuracy.

[0043] 8. Actuator solution: suitable for medium-sized turbine housings (outer diameter 80~150mm), circumferential interval 45°, good balance correction effect, and the best balance between response speed and cost.

[0044] 12-actuator solution: suitable for large or ultra-thin wall turbine housings (outer diameter ≥ 150 mm), with a circumferential interval of 30°, which can achieve high-precision harmonic vibration suppression, but the controller has a large number of channels and the cost is high.

[0045] In conclusion, the 8-actuator scheme yields the best results.

[0046] The arc-shaped lobe 264 makes movable contact with the outer surface of the load-bearing rotating shaft 25 via a piezoelectric ceramic stacked actuator 263, and the arc-shaped lobe 264 undergoes radial displacement via the voltage-applied piezoelectric ceramic stacked actuator 263. In some embodiments, the connection between the arc-shaped lobe 264 and the piezoelectric ceramic stacked actuator 263 employs a spherical flexible hinge, allowing for minute angular displacement while maintaining radial displacement, accommodating irregular deformation of the shaft. Each arc-shaped lobe 264 also has an anti-rotation pin on its side to prevent the arc-shaped lobe 264 from rotating in the circumferential direction.

[0047] The synchronization chain 296 is U-shaped via the steering sprocket 295.

[0048] The ultrasonic vibration auxiliary device 4 is used to drive the cutter 48 to perform cutting operations around the tubular turbocharger housing. The second three-dimensional moving bracket 41 drives the guide semi-ring 42 and the telescopic semi-ring 43, so that the cutter 48 can perform periodic reciprocating rotation around the tubular turbocharger housing from 0° to 120°. It is suitable for difficult-to-machine materials such as high-silicon ductile iron and Ni-Resist cast iron.

[0049] In some embodiments, the ultrasonic vibration assist device 4 includes a second three-dimensional moving support 41 movably mounted on the body 1. The second three-dimensional moving support 41 is identical to the first three-dimensional moving support 32 and is independently controlled to achieve spatial positioning of the cutter 48. A guide semi-ring 42 is provided on the second three-dimensional moving support 41, and a telescopic semi-ring 43 is slidably fitted in the guide semi-ring 42. It should be noted that the two are engaged by a sliding guide rail with a dovetail or T-shaped cross-section, and the gap is adjustable to ensure smooth extension and contraction without shaking.

[0050] The driving method for the telescopic semi-ring 43 is as follows: a semi-ring rack 44 is integrally connected to the outer wall of the telescopic semi-ring 43, and a drive gear 45 that meshes with the semi-ring rack 44 is rotatably installed in the guide semi-ring 42. The drive gear 45 is driven by a servo motor and forms a gear and rack transmission with the semi-ring rack 44. The telescopic speed of the telescopic semi-ring 43 is adjustable, and the maximum telescopic stroke is designed to be 1.2 times the diameter of the tubular turbocharger housing.

[0051] A piezoelectric ceramic transducer 46 is fixedly mounted on the telescopic semi-ring 43. The piezoelectric ceramic transducer 46 adopts a sandwich-type piezoelectric ceramic stack, which is provided with a 20~40kHz sine wave excitation by an ultrasonic power supply. The power is adjustable from 100~500W and is equipped with an automatic frequency tracking module. An amplitude transformer 47 is movably mounted on the telescopic semi-ring 43, which is connected to the output end of the piezoelectric ceramic transducer 46 and is used to fix the cutter 48. The amplitude transformer 47 adopts an exponential or stepped design, is made of high-strength titanium alloy, has a magnification of 3~8 times, and an end-face output amplitude of 5~30μm.

[0052] In some embodiments, the ultrasonic vibration is multi-directionally combined by the ultrasonic vibration aid 4 to achieve: Axial ultrasonic vibration: The cutter 48 vibrates along the spindle axis, suitable for end face turning and axial groove machining.

[0053] Radial ultrasonic vibration: The cutter 48 vibrates radially, which is suitable for external turning and can effectively reduce radial cutting force.

[0054] Elliptical ultrasonic vibration (axial + radial, phase difference 90°): the preferred method, the cutting edge forms an elliptical trajectory, which can ensure smoother chip removal.

[0055] It should be noted that the specific models and specifications of the microcontroller 266, power amplifier 267, piezoelectric ceramic transducer 46, and cutter 48 need to be selected and determined according to the actual specifications of the device. The specific selection and calculation methods use existing technology in this field, so they will not be elaborated here.

[0056] To verify the technological advancements of this invention, a comparative cutting test was conducted using the same high-silicon ductile iron tubular turbocharger housing (outer diameter 120mm, wall thickness 4mm, length 180mm). The test conditions are as follows: Evaluation indicators Existing technology 1 Existing technology 2 This invention Increase Surface roughness Ra (μm) of the machined surface 0.85 0.92 0.28 ↓ 69.5% Tool life (pieces / cutting edge) 32 28 96 ↑ 200% Average cutting force (N) 285 302 158 ↓ 47.7% Flutter amplitude (μm) 18 22 3.5 ↓ 84.1% Machining accuracy level IT8~IT9 IT8~IT9 IT6 Increase by 2-3 levels Finished product yield (%) 86% 83% 98.5% ↑ 15% It can be seen that the experiment was conducted under the same ambient temperature (20±1℃) and the same batch of cutting tools (PCBN). The average value was taken after machining 20 tubular turbocharger housings in each group of experiments. The present invention is significantly superior to the prior art in all indicators, especially the chatter amplitude is reduced by more than 84%, and the surface roughness reaches 0.28μm, which is close to the mirror effect.

[0057] The functional principle of this invention can be explained through the following operational methods: The tubular turbocharger housing, made of high-silicon ductile iron and Ni-Resist cast iron, is placed between the two sets of limit adjustment parts 2. The movable support frames 21 on the left and right sides slide laterally along the guide rail on the body 1 and are roughly positioned to match the distance of the tubular turbocharger housing. Rotating the traction lever 22 causes the lifting slider 23 to slide vertically on the movable support frame 21 via the traction rod 24, aligning the center height of the load-bearing shaft 25 with the theoretical center of the tubular turbocharger housing port. This pushes the drive slider 28 inside the load-bearing shaft 25 to move axially. The drive slider 28 pulls the elastic guide sleeve 292 via the traction link 294, causing it to slide outward along the double-layer guide elongated hole 291 in the load plate 27. The elastic guide sleeve 292 drives the synchronous chain 296 connected to it. The synchronous chain 296 bypasses the steering sprocket 295 and reverses direction, pulling the wear-resistant clamp 293 on the other side in the opposite direction, causing the wear-resistant clamp 293 to slide inward along the double-layer guide elongated hole 291. During this process, the silicone expansion plate 297 installed in the elastic guide sleeve 292 expands radially from the inside to the outside under the constraint of the limiting connecting rod 298, tightening the inner wall of the tubular turbocharger housing port, and the wear-resistant clamping plate 293 closes from the outside to the inside, clamping the outer wall of the tubular turbocharger housing port, realizing the radial centering and axial locking of the tubular turbocharger housing, and completing the stable clamping of the workpiece.

[0058] It should be noted that before driving the slider 28 to move, the CNC system first checks whether the lifting sliders 23 on the left and right sides are at the same height (by comparing with a grating ruler). The allowable deviation is ≤0.05mm; otherwise, an alarm is issued and the next step is prohibited.

[0059] The drive shaft 25 rotates, causing the load-bearing disc 27 and the clamped tubular turbocharger housing to rotate together. The high-viscosity silicone oil filled in the microfluidic annular channel 261 experiences annular flow due to the shaft's unbalanced vortex. Circumferentially distributed hot-wire flow rate sensors 262 detect the real-time flow rate differences of the high-viscosity silicone oil, outputting an electrical signal reflecting the shaft's vortex angular velocity to the microcontroller 266. A piezoelectric thin-film sensor 265, attached to the inner surface of the arc-shaped lobes 264, monitors the real-time pressure distribution between itself and the outer surface of the load-bearing shaft 25, and transmits the pressure... The force signal is sent to the microcontroller 266. The microcontroller 266, in conjunction with the power amplifier 267, calculates the direction and magnitude of the unbalanced force based on the flow velocity and pressure signals. Different voltages are applied to the circumferentially equidistantly distributed piezoelectric ceramic stacked actuators 263 (4-12 in total), causing them to extend and retract radially. This drives the connected arc lobes 264 to move. All arc lobes 264 together form a floating inner support ring. After local radial displacement, the ring counteracts the eccentric vibration of the shaft, ensuring that the load-bearing rotating shaft 25 always rotates in the center, achieving millisecond-level active stabilization. The clamping force is set to 500–800 N and is fed back to the microcontroller 266 via a pressure sensor installed between the drive slider 28 and the load-bearing rotating shaft 25.

[0060] During the clamping process, the microcontroller 266 monitors the stroke of the drive slider 28 in real time through the displacement sensor and compares it with the preset diameter of the tubular turbocharger housing. When the clamping force reaches the set value, the servo valve of the hydraulic cylinder or electric push rod closes and locks, and the clamping completion indicator light illuminates. If the clamping force deviation on the left and right sides exceeds 10%, the driving pressure on one side is automatically adjusted to achieve uniform clamping.

[0061] The first three-dimensional moving support 32 moves on the machine body 1, driving the self-locking slider 33 to move, so that the amplitude adjustment plate 35 is roughly aligned with the part to be processed of the tubular turbocharger housing. The drive gear 37 on the self-locking slider 33 rotates, driving the driven gear 34 that meshes with it, thereby driving the amplitude adjustment plate 35 to rotate around its own axis to the required spray angle. The two media (water-based coolant and vegetable oil-based lubricant) in the supply tank 31 are respectively delivered to the booster nozzle 38 on the amplitude adjustment plate 35 through the corrugated hose 36.

[0062] The second three-dimensional moving support 41 drives the guide semi-ring 42 to move to the part of the tubular turbocharger housing to be machined. The drive gear 45 rotates, driving the semi-ring rack 44, so that the telescopic semi-ring 43 extends out from the guide semi-ring 42 and surrounds the outer wall of the tubular turbocharger housing. The cutter 48 is fixed on the amplitude transformer 47, which is connected to the piezoelectric ceramic transducer 46. The piezoelectric ceramic transducer 46 converts the high-frequency electrical signal into mechanical vibration. After being amplified by the amplitude transformer 47, it drives the cutter 48 to generate ultrasonic vibration of 20-40kHz and amplitude of 5-30μm. The telescopic semi-ring 43 drives the cutter 48 to reciprocate around the turbine housing axis from 0° to 120°, while completing the axial feed. Ultrasonic-assisted turning is performed on the high-silicon ductile iron / Ni-Resist cast iron material. The ultrasonic vibration causes the cutter 48 tool to periodically separate from the tubular turbocharger housing, reducing the average cutting force and suppressing chatter of the thin-walled structure.

[0063] Furthermore, the reciprocating rotation angle and speed of the telescopic semi-ring 43 are set by the CNC system based on the three-dimensional model of the tubular turbocharger housing: a large 120° reciprocating angle with a fast feed rate is used in the roughing stage; a small 60° reciprocating angle with a slow feed rate is used in the finishing stage. The tool tip trajectory of the cutter 48 is generated by a post-processor to ensure close contact with the complex curved surface of the tubular turbocharger housing.

[0064] During the movement of the cutter 48, the first three-dimensional moving support 32 and the self-locking slider 33 follow in real time, ensuring that the pressurizing nozzle 38 always points towards the cutting area. The first nozzle 381 sprays water-based coolant in the form of water droplets to reduce the temperature of the cutting area, while the second nozzle 382 sprays vegetable oil-based lubricant in the form of aerosol to penetrate the cutter 48 and the cutting interface to reduce friction. Throughout the cutting process, the piezoelectric thin film sensor 265 and the flow rate sensor 262 continuously monitor vibration and pressure changes. The microcontroller 266 can adjust in real time based on the feedback signals. The frequency and amplitude of ultrasonic vibration (by changing the excitation signal of the piezoelectric ceramic transducer 46); the voltage of the piezoelectric ceramic stacked actuator 263 (to maintain shaft stability); and, if necessary, reducing the feed rate (by communicating with the CNC system).

[0065] The above-mentioned closed-loop adaptive control, which forms a perception-decision-execution mechanism, ensures machining accuracy and surface quality.

[0066] After the cutter 48 completes the set trajectory, the telescopic semi-ring 43 retracts to the guide semi-ring 42, the second three-dimensional moving bracket 41 resets, the drive slider 28 moves in the opposite direction, the locking clamp 29 is released, and the machined turbocharger housing is removed.

[0067] Before unloading, the load-bearing rotating shaft 25 stops rotating, and then the piezoelectric ceramic stacked actuator 263 of the bionic adaptive bearing 26 is de-energized and reset, causing the arc petal 264 to disengage from the load-bearing rotating shaft 25. Afterwards, the drive slider 28 moves in the opposite direction, and the silicone outer expansion plate 297 and wear-resistant clamping plate 293 are released simultaneously, causing the turbocharger housing to automatically fall onto the unloading bracket.

[0068] Throughout the entire processing, all sensor data is recorded in the memory card of the microcontroller 266, allowing for quality traceability.

[0069] The above description is only a preferred embodiment of the present invention, but the scope of protection of the present invention is not limited thereto. Any equivalent substitutions or modifications made by those skilled in the art within the scope of the technology disclosed in the present invention, based on the technical solution and inventive concept of the present invention, should be covered within the scope of protection of the present invention.

Claims

1. A cutting device for automotive parts, comprising a body (1) for cutting a tubular turbocharger housing, wherein a cutter (48) is disposed at the front of the body (1), and the cutter (48) reciprocates periodically around the tubular turbocharger housing from 0° to 120°, characterized in that, Also includes: Two sets of limit adjustment parts (2) are symmetrically distributed on the left and right sides of the body (1). Each set includes a lifting slider (23), a load-bearing rotating shaft (25), and at least two sets of locking clamps (29). The lifting slider (23) is provided with a bionic adaptive bearing (26) for maintaining the load-bearing rotating shaft (25) in a centered rotation. The locking clamps (29) include a silicone outward expansion plate (297) and a wear-resistant clamping plate (293). The silicone outward expansion plate (297) expands from the inside to the outside to support the tubular turbocharger housing port, and the wear-resistant clamping plate (293) closes from the outside to the inside to clamp the tubular turbocharger housing port. Cooling and lubrication section (3) is movably disposed at the rear side of the body (1). It includes a supply tank (31) and an amplitude adjustment plate (35) connected by a corrugated hose (36). The amplitude adjustment plate (35) is provided with a booster nozzle (38) for spraying cooling and lubricating agent onto the cutting part of the tubular turbocharger housing according to the cutter (48).

2. The automotive parts cutting equipment according to claim 1, characterized in that, The limit adjustment part (2) also includes a movable support frame (21), which is slidably mounted on the machine body (1) in a left-right direction, and the lifting slider (23) is slidably mounted on the movable support frame (21) in a longitudinal direction.

3. The automotive parts cutting equipment according to claim 2, characterized in that, The biomimetic adaptive bearing device (26) includes a microfluidic annular channel (261) opened in the lifting slider (23) and filled with high viscosity silicone oil. Multiple circumferentially equidistant flow velocity sensors (262) are fixedly arranged on the outer side of the inner wall of the microfluidic annular channel (261). A piezoelectric ceramic stacked actuator (263) electrically connected to the flow velocity sensors (262) is fixedly arranged on the inner side of the inner wall of the microfluidic annular channel (261). An arc petal (264) for forming a floating inner support ring around the load-bearing rotating shaft (25) is fixedly connected to the output end of the piezoelectric ceramic stacked actuator (263). A piezoelectric thin film sensor (265) is attached to the inner surface of the arc petal (264). A microcontroller (266) and a power amplifier (267) electrically connected to the flow velocity sensor (262) and the piezoelectric thin film sensor (265) are arranged on the lifting slider (23).

4. The automotive parts cutting equipment according to claim 3, characterized in that, The flow sensor (262) is a hot wire flow sensor, which is used to detect the annular flow of high-viscosity silicone oil fluid caused by shaft vibration.

5. The automotive parts cutting equipment according to claim 4, characterized in that, The number of the piezoelectric ceramic stacked actuators (263) is 4-12, and they are equidistantly distributed in the circumferential direction.

6. The automotive parts cutting equipment according to claim 5, characterized in that, The arc lobe (264) makes active contact with the outer surface of the load-bearing rotating shaft (25) through the piezoelectric ceramic stack actuator (263), and the arc lobe (264) undergoes radial displacement through the piezoelectric ceramic stack actuator (263) under applied voltage.

7. The automotive parts cutting equipment according to claim 6, characterized in that, The load-bearing shaft (25) is integrally connected to a load-bearing disc (27), and the load-bearing disc (27) is slidably mounted with an elastic guide sleeve (292) of a movable silicone outer expansion plate (297). The elastic guide sleeve (292) is connected to the wear-resistant clamping plate (293) by a synchronous chain (296).

8. The automotive parts cutting equipment according to claim 7, characterized in that, The load disk (27) is rotatably mounted with a steering sprocket (295) that meshes with the synchronous chain (296). The synchronous chain (296) has a U-shaped structure through the steering sprocket (295).

9. The automotive parts cutting equipment according to claim 8, characterized in that, The cooling and lubrication section (3) further includes a first three-dimensional moving bracket (32) movably mounted on the body (1), and a self-locking slider (33) for rotating and mounting the amplitude adjustment plate (35) is movably mounted on the first three-dimensional moving bracket (32).

10. The automotive parts cutting equipment according to claim 9, characterized in that, The body (1) is also provided with an ultrasonic vibration auxiliary device (4) for driving the cutter (48) to perform cutting operations around the tubular turbocharger housing. The ultrasonic vibration auxiliary device (4) includes a second three-dimensional moving bracket (41) movably mounted on the body (1). A guide semi-ring (42) is provided on the second three-dimensional moving bracket (41). A telescopic semi-ring (43) is slidably fitted in the guide semi-ring (42). A piezoelectric ceramic transducer (46) is fixedly mounted on the telescopic semi-ring (43). An amplitude rod (47) is movably mounted on the telescopic semi-ring (43) and connected to the output end of the piezoelectric ceramic transducer (46) for fixing the cutter (48).

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