An ultrasonic vibration assisted scratch test bench and method

Abstract

The application belongs to the technical field of material surface performance testing, and discloses an ultrasonic vibration assisted scratch test bench and method. The test bench comprises: an X-axis transmission component directly connected with an X-axis ultrasonic module through mechanical structure, which simplifies the vibration transmission path, directly transmits the vibration energy to the workpiece, and controls the speed of the scratch through the X-axis transmission component; a Y-axis transmission component directly connected with a Y-axis ultrasonic module through mechanical structure, which simplifies the vibration transmission path, directly transmits the vibration energy to the workpiece, and realizes the scratch at different positions in the Y-axis through the Y-axis transmission component; and a Z-axis transmission component directly connected with a Z-axis ultrasonic module through mechanical structure, which simplifies the vibration transmission path, directly loads the vibration energy to the workpiece, and completes the loading in the Z-axis direction through the Z-axis transmission component. The application provides guidance for the application of ultrasonic vibration machining technology in difficult-to-machine materials and brittle and hard materials.

Description

Technical Field

[0001] This invention belongs to the field of material surface performance testing technology, and particularly relates to an ultrasonic vibration-assisted scratch test bench and method. Background Technology

[0002] The core purpose of traditional scratch testing benches is to simulate the process of materials being subjected to external forces under normal conditions by controlling parameters such as scratch head load and speed, in order to reveal their removal mechanisms, such as brittle fracture of composite materials and ceramics. As a typical device for characterizing material removal mechanisms, it can quantify key parameters such as scratch hardness and critical load, and combine microscopic observation to record surface morphology, intuitively reflecting the microscopic mechanism of material removal. This provides a controllable experimental environment and key data support for material selection, process optimization, and new material development, and is an important tool for studying the mechanical properties and removal behavior of materials.

[0003] Today, difficult-to-machine materials such as ceramics and composite materials are widely used in the automotive and aerospace industries. These materials are characterized by high hardness and brittleness. During machining, brittle materials exhibit two material removal mechanisms: a brittle mode and a ductile mode. When machining parameters such as load and depth of cut change, the material rapidly transitions from the ductile to the brittle domain. At large depths of cut, the material undergoes brittle fracture and is removed in the brittle mode. However, if the machining scale is sufficiently small, and the depth of cut is less than a certain critical value, the material first undergoes plastic deformation and is removed in the ductile mode. Because ductile machining does not involve brittle fracture, it avoids damage to the surface and subsurface layers of the part and the generation of microcracks, significantly improving the surface quality and precision of the machined material.

[0004] Ultrasonic vibration machining exhibits significant advantages in the processing of brittle materials. Its high-frequency vibration can effectively alter the contact state between the tool and the material, expanding the scale for removing ductile domains in brittle materials by reducing cutting forces and inhibiting crack propagation. This provides a feasible path for high-quality machining of hard and brittle materials such as ceramics and composites. However, there are obvious limitations when conducting experiments using macroscopic ultrasonic vibration cutting. The difficulty in accurately capturing the microscopic dynamics of material removal at the macroscopic scale, such as dislocation motion and microcrack initiation, leads to inaccurate characterization of the microscopic material removal mechanism. This hinders the in-depth revelation of the intrinsic relationship between ultrasonic vibration and ductile domain removal, limiting the targeted nature of technology optimization. Summary of the Invention

[0005] To overcome the problems existing in related technologies, this invention discloses an ultrasonic vibration-assisted scratch testing bench and method, specifically involving a scratch testing bench integrating ultrasonic vibration technology and a precision transmission structure. The purpose of this invention is to integrate a high-frequency ultrasonic vibration module with a precision micro-scraping mechanism, thereby leveraging the high-frequency impact effect of ultrasonic vibration to control the material removal process and providing a controllable environment for exploring the ductile domain removal law of brittle materials under vibration excitation. By relying on the precise control of parameters such as load and displacement in traditional scratch testing benches, the synergistic effect of scratching behavior and ultrasonic vibration at the microscale is achieved.

[0006] The technical solution is as follows: an ultrasonic vibration-assisted scratch testing bench, the testing bench comprising: It is directly connected to the X-axis ultrasonic module using a mechanical structure, which simplifies the vibration transmission path and allows the vibration energy to be directly transmitted to the X-axis transmission component of the workpiece. The speed of the scratch is controlled through this X-axis transmission component. The Y-axis ultrasonic module is directly connected to it using a mechanical structure, which simplifies the vibration transmission path and allows the vibration energy to be directly transmitted to the Y-axis transmission component of the workpiece. The Y-axis transmission component is used to achieve rubbing at different positions on the Y-axis. The Z-axis ultrasonic module is directly connected to it using a mechanical structure, which simplifies the vibration transmission path and allows the vibration energy to be directly applied to the Z-axis transmission component of the workpiece. The Z-axis load is then applied through this Z-axis transmission component.

[0007] Furthermore, the X-axis transmission component provides power to the X-axis by connecting the X-axis servo motor to the two-stage reducer; The workpiece is fixed on the part fixture table. The two-stage reducer and the X-axis slider plate convert the circular motion of the gear into linear motion through the transmission of gears and racks. The X-axis slider plate is connected to the X-axis linear guide rail, so that the X-axis moves on the linear guide rail, realizing the transmission in the X-axis direction and controlling the X-axis scratch length of the workpiece fixed on the part fixture table.

[0008] Furthermore, the Y-axis transmission component includes a Y-axis servo motor, which is connected to the Y-axis ball screw via a coupling. The servo motor drives the screw on the Y-axis ball screw to rotate, and the balls on the screw roll in the thread raceway, causing the moving component Y-axis slide connected to the nut to move linearly on the Y-axis linear guide, thus completing the transmission in the Y-axis direction and realizing scrubbing at different positions on the Y-axis.

[0009] Furthermore, the Z-axis transmission component transmits the output torque to the Z-axis ball screw through the Z-axis servo motor and gears. The Z-axis ball screw converts the rotational motion of the Z-axis servo motor into linear motion, causing the Z-axis ultrasonic module to move along the Z-axis linear guide rail, thus completing the loading in the Z-axis direction.

[0010] Furthermore, the applied force is monitored by a strain gauge pressure sensor installed at the end of the mechanical structure and controlled in real time by a Z-axis servo motor.

[0011] Furthermore, by using any combination of the X-axis ultrasonic module, X-axis transmission component, Y-axis ultrasonic module, Y-axis transmission component, Z-axis ultrasonic module, and Z-axis transmission component, vibration environments under different working conditions can be simulated through XY-axis horizontal plane coupling, XZ / YZ-axis horizontal-vertical coupling, or XYZ three-axis spatial coupling.

[0012] Furthermore, the ultrasonic vibration-assisted scratch test bench also includes: a base shell for supporting the X-axis ultrasonic module, X-axis transmission component, Y-axis ultrasonic module, Y-axis transmission component, Z-axis ultrasonic module, and Z-axis transmission component, with adjustable feet at the four corners of the bottom of the base shell.

[0013] Another object of the present invention is to provide a scratching method for an ultrasonic vibration-assisted scratch testing bench, the method comprising: By directly connecting the X-axis transmission component and the X-axis ultrasonic module using a mechanical structure, the vibration transmission path is simplified, allowing the vibration energy to be directly transferred to the workpiece and controlling the scratch speed. By directly connecting the Y-axis transmission component and the Y-axis ultrasonic module using a mechanical structure, the vibration transmission path is simplified, allowing the vibration energy to be directly transferred to the workpiece, thus achieving scratching at different positions on the Y-axis. By directly connecting the Z-axis transmission component and the Z-axis ultrasonic module using a mechanical structure, the vibration transmission path is simplified, allowing the vibration energy to be directly applied to the workpiece, thus completing the loading in the Z-axis direction.

[0014] The X-axis, Y-axis, and Z-axis ultrasonic modules have a vibration frequency of 40kHz and an amplitude of 0-5μm. The amplitude can be precisely controlled by adjusting the input voltage of the ultrasonic generator, and the voltage can be flexibly increased or decreased according to actual needs to match the vibration intensity of different scenarios.

[0015] The ultrasonic vibration-assisted scratch test bench is used for scratching methods in the processing of difficult-to-machine materials, brittle and hard materials, and materials at the microscale.

[0016] Combining all the above technical solutions, the beneficial effects of this invention are as follows: This invention combines ultrasonic vibration technology with a traditional scratch testing platform to construct an experimental system capable of simultaneously performing microscale scratching and ultrasonic vibration. By integrating a high-frequency ultrasonic vibration module with a precision micro-scraping mechanism, this system can utilize the high-frequency impact effect of ultrasonic vibration to control the material removal process, providing a controllable environment for exploring the ductile domain removal characteristics of brittle materials under vibration excitation.

[0017] This invention is primarily used to detect the material removal mechanism of various materials, such as difficult-to-machine metals, ceramics, and composite materials, under ultrasonic vibration conditions. The core of this technology lies in integrating a triaxial ultrasonic vibrator with traditional scratch testing, overcoming the limitations of traditional equipment in ultrasonic vibration environments, and providing a reliable performance evaluation method for the research and development and processing of new materials.

[0018] The overall structure of the test bench is designed around the three-in-one approach of vibration, loading, and motion: the ultrasonic vibration system, as the core of energy conversion, consists of a piezoelectric ceramic transducer and a stepped amplitude transformer. The transducer is responsible for converting high-frequency electrical signals into mechanical vibrations, while the amplitude transformer amplifies the vibration through structural optimization, ensuring efficient transmission of vibration energy to the workpiece clamping platform and probe; the loading system adopts a transmission method combining servo motors, gear reduction, and ball screws to achieve precise application of loads to the sample, meeting the diverse requirements of different materials for loading force and scratching speed; the multi-axis linkage motion platform consists of X-axis and Y-axis displacement mechanisms, with transmission methods designed for different motion accuracy requirements, working in conjunction with the control system to achieve precise positioning of the scratch trajectory; the control system coordinates the operating parameters of each part, dynamically adjusting the equipment status by real-time monitoring of vibration frequency, amplitude, and loading force to ensure the stability of the testing process.

[0019] This invention introduces ultrasonic vibration into scratch testing, improving the flow stress state during material removal through high-frequency vibration, thereby enhancing material machinability. It provides guidance for the application of ultrasonic vibration processing technology in difficult-to-machine and brittle materials, and addresses the high-precision testing requirements of materials at the microscale, thus promoting the development of ultrasonic vibration technology towards higher precision and wider application scenarios.

[0020] Currently, research on the mechanism of ultrasonic vibration-assisted material removal is limited to the macroscopic orthogonal ultrasonic vibration-assisted cutting level and simulation studies of the microscopic ultrasonic vibration-assisted material removal mechanism. The technical solution of this invention fills the equipment gap for accurate characterization of the ultrasonic vibration material removal mechanism at the microscopic scale, providing practical technical support for experimental research in this field. In terms of equipment for accurate characterization of the ultrasonic vibration material removal mechanism at the microscopic scale, this invention provides a controllable environment for exploring the ductile domain removal law of brittle materials under vibration excitation. Attached Figure Description

[0021] The accompanying drawings, which are incorporated in and form part of this specification, illustrate embodiments consistent with this disclosure and, together with the description, serve to explain the principles of this disclosure; Figure 1 This is a schematic diagram of the ultrasonic vibration-assisted scratch testing bench provided in an embodiment of the present invention; Figure 2 This is a schematic diagram of the XY axis structure of the ultrasonic vibration-assisted scratch test bench provided in an embodiment of the present invention; Figure 3 This is a schematic diagram of the Z-axis structure of the ultrasonic vibration-assisted scratch test bench provided in an embodiment of the present invention; In the diagram: 1. Base housing; 2. Adjustable feet; 3. Y-axis servo motor; 4. Coupling; 5. Y-axis ball screw; 6. Y-axis linear guide; 7. Y-axis slide; 8. X-axis slide; 9. Two-stage reducer; 10. X-axis servo motor; 11. X-axis linear guide; 12. X-axis ultrasonic module; 13. Parts fixture table; 14. Y-axis ultrasonic module; 15. Z-axis servo motor; 16. Gear; 17. Z-axis linear guide; 18. Z-axis ball screw; 19. Z-axis ultrasonic module; 20. Strain gauge pressure sensor. Detailed Implementation

[0022] To make the above-mentioned objects, features, and advantages of the present invention more apparent and understandable, specific embodiments of the present invention will be described in detail below with reference to the accompanying drawings. Many specific details are set forth in the following description to provide a thorough understanding of the present invention. However, the present invention can be practiced in many other ways different from those described herein, and those skilled in the art can make similar modifications without departing from the spirit of the present invention. Therefore, the present invention is not limited to the specific embodiments disclosed below.

[0023] The innovation of this invention lies in the construction of an integrated system of vibration, loading, and motion. Through the mechanical structure connection design of the X, Y, and Z-axis ultrasonic modules and corresponding transmission components, the vibration transmission path is simplified and energy loss is reduced. Combined with a customized precision transmission scheme for each axis and a strain gauge pressure sensor 20, the load is precisely applied, thereby achieving precise control of scratch speed, position, and loading force. It supports multi-dimensional vibration coupling modes and ultrasonic parameter configurations with a fixed frequency of 40kHz and adjustable amplitude of 0-5μm. Addressing the limitations of traditional macroscale equipment in accurately capturing the microscopic mechanisms of material removal, such as dislocation motion and microcrack initiation, leading to insufficient accuracy in characterizing microscopic material removal mechanisms, this invention achieves a technological breakthrough. It can accurately characterize the intrinsic laws of ultrasonic vibration and ductile domain removal at the microscopic scale, providing a reliable testing method for the study of removal mechanisms and the optimization of processing techniques for difficult-to-machine and brittle-hard materials.

[0024] Example 1, as Figures 1-3 As shown, the ultrasonic vibration-assisted scratch testing bench provided in this embodiment of the invention includes: The X-axis ultrasonic module 12 is directly connected to it by a mechanical structure, which simplifies the vibration transmission path and allows the vibration energy to be directly transmitted to the X-axis transmission component of the workpiece. The speed of the scratch is controlled by the X-axis transmission component. The Y-axis ultrasonic module 14 is directly connected to it by a mechanical structure, which simplifies the vibration transmission path and allows the vibration energy to be directly transmitted to the Y-axis transmission component of the workpiece. The Y-axis transmission component is used to achieve rubbing at different positions on the Y-axis. The Z-axis ultrasonic module 19 is directly connected to it by a mechanical structure, which simplifies the vibration transmission path and allows the vibration energy to be directly applied to the Z-axis transmission component of the workpiece. The Z-axis load is then applied through this Z-axis transmission component.

[0025] The base housing 1 is used to support the X-axis ultrasonic module 12, X-axis transmission components, Y-axis ultrasonic module 14, Y-axis transmission components, Z-axis ultrasonic module 19, and Z-axis transmission components. The four bottom corners of the base housing 1 are adjustable feet 2.

[0026] The workpiece is fixed on the part fixture table 13, and the XY direction ultrasonic system (including the X-axis ultrasonic module 12 and the Y-axis ultrasonic module 14) is installed as follows. Figure 2 As shown, the Y-axis ultrasonic module 14 and X-axis ultrasonic module 12 are connected to the workpiece fixture table 13 via a mechanical structure, simplifying the vibration transmission path. This direct connection allows vibration energy to be transferred to the workpiece, preventing vibration loss or instability and ensuring consistent and reliable vibration in the X and Y axes. This enables the workpiece to vibrate in the X and Y directions.

[0027] For example, the X-axis transmission component employs a transmission scheme combining a motor and a two-stage reducer. The X-axis servo motor 10 is connected to the two-stage reducer 9 to provide power to the X-axis and simultaneously control the scratch speed. The two-stage reducer 9 and the X-axis slider plate 8 are connected via a gear 16 and a rack to convert the circular motion of the gear 16 into linear motion. The X-axis slider plate 8 is connected to the X-axis linear guide rail 11, allowing the X-axis to move on the linear guide rail, thereby achieving transmission in the X-axis direction to control the length of the scratch.

[0028] For example, the Y-axis transmission component uses a motor + ball screw transmission method. The Y-axis servo motor 3 is connected to the Y-axis ball screw 5 through a coupling 4. The transmission is achieved through the balls on the screw between the screw and the nut on the Y-axis ball screw 5. When the Y-axis servo motor 3 drives the screw on the Y-axis ball screw 5 to rotate, the balls on the screw roll in the thread raceway, causing the moving component Y-axis slide 7 connected to the nut to move linearly on the Y-axis linear guide 6, thereby realizing transmission in the Y-axis direction, changing the position of the scratch, and realizing scratching at different positions.

[0029] For example, the structure of the Z-axis transmission component needs to meet both loading and motion conditions, employing a motor + gear 16 + ball screw transmission method. The Z-axis servo motor 15 is connected to the Z-axis ball screw 18 via gear 16. The addition of gear 16 is mainly to utilize the rotation of gear 16 to achieve output torque, thereby increasing the output torque of the Z-axis. The Z-axis ball screw 18 accurately converts the rotational motion of the Z-axis servo motor 15 into linear motion, causing the Z-axis ultrasonic module 19 (Z-axis ultrasonic vibration system) to move along the Z-axis linear guide rail 17, thus realizing loading in the Z-axis direction. The technical means of monitoring the loading force through strain gauge pressure sensor 20 and achieving precise control by Z-axis servo motor 15 is mainly based on the closed-loop control principle, involving four key links: real-time detection, signal processing, intelligent decision-making, and mechanical execution.

[0030] Specifically, the strain gauge pressure sensor 20 is directly installed at the Z-axis loading end of the mechanical structure. It acquires pressure signals in real time through changes in the resistance of the strain gauge and converts the mechanical deformation into an electrical signal output. After amplification, filtering, and analog-to-digital conversion, this signal is compared with a preset target force value by the control system to calculate the deviation. After receiving the command, the Z-axis servo motor 15 drives the Z-axis ball screw 18 through gear 16 to increase torque, converting the rotational motion into linear displacement, thereby precisely controlling the loading force. The entire system ensures that the loading force remains stable at the target value through a closed-loop process of "detection-feedback-adjustment".

[0031] Example 2, another exemplary embodiment, involves fixing the workpiece to the parts fixture table 13, with the Z-axis ultrasonic system installed as follows: Figure 3 The Z-axis ultrasonic module 19 and strain gauge pressure sensor 20 are mechanically connected to the Z-axis transmission system (including Z-axis servo motor 15, gear 16, Z-axis linear guide 17, and Z-axis ball screw 18). The Z-axis ultrasonic module 19 (including Z-axis ultrasonic vibration generator) is directly connected to the tool or indenter. In this way, the tool or indenter can vibrate in the Z-axis direction, thereby ensuring that ultrasonic vibration processing can be achieved in machining or testing.

[0032] The X-axis drive employs a transmission scheme combining a motor and a two-stage reducer. The X-axis servo motor 10 is connected to the two-stage reducer 9 to provide power to the X-axis and simultaneously control the scratching speed. The two-stage reducer 9 and the X-axis slider plate 8 are connected via a gear 16 and a rack to convert the circular motion of the gear 16 into linear motion. The X-axis slider plate 8 is connected to the X-axis linear guide rail 11, allowing the X-axis to move on the linear guide rail, thereby achieving transmission in the X-axis direction.

[0033] The Y-axis drive uses a motor + ball screw transmission method. The Y-axis servo motor 3 is connected to the Y-axis ball screw 5 through the coupling 4. The transmission is achieved through the balls on the screw between the screw and the nut. When the servo motor drives the screw to rotate, the balls on the screw roll in the thread raceway, causing the moving parts connected to the nut to make linear motion. This causes the Y-axis slide 7 to make linear motion on the Y-axis linear guide 6, thereby realizing the transmission in the Y-axis direction, changing the position of the scratch, and realizing scratching at different positions.

[0034] The Z-axis structure needs to meet both loading and motion requirements. It employs a motor + gear 16 + ball screw transmission method. The Z-axis servo motor 15 is connected to the Z-axis ball screw 18 via gear 16. The addition of gear 16 primarily utilizes its rotation to achieve output torque, thereby increasing the output torque of the Z-axis. The ball screw accurately converts the motor's rotational motion into linear motion, causing the Z-axis ultrasonic vibration system to move along the Z-axis linear guide rail 17, thus achieving loading in the Z-axis direction. The magnitude of the load is monitored by a strain gauge pressure sensor 20, and the servo motor 15 adjusts the loading force accordingly.

[0035] This invention employs ultrasonic vibration technology. The vibration transmission route is as follows: the ultrasonic generator converts the power frequency electrical signal into a high-frequency electrical signal, which is then converted into mechanical vibration by the ultrasonic transducer. The amplitude is amplified by the amplitude transformer and transmitted to the actuator, achieving efficient transmission. The core process parameters are a vibration frequency of 40kHz and an amplitude of 0-5μm. The amplitude is precisely controlled by adjusting the input voltage of the ultrasonic generator. The voltage can be flexibly increased or decreased according to actual needs to match the vibration intensity of different scenarios, ensuring the desired effect. The XY-axis ultrasonic system has a very complex mechanical structure connecting the vibration generator (X-axis ultrasonic module 12, Y-axis ultrasonic module 14) and the tooling table (Y-axis slide 7, X-axis slide 8). Vibration energy can be directly transmitted to the vibration receiver (workpiece). Direct transmission of vibration energy increases vibration efficiency and simplifies the vibration transmission path, preventing vibration loss or instability caused by complex path connections. This ensures consistent controllability of workpiece vibration in the X and Y axes, meeting the vibration requirements of ultrasonic vibration table vibration processing or ultrasonic vibration test table vibration processing of the tooling.

[0036] The Z-axis design involves an ultrasonic generator converting a power frequency electrical signal into a high-frequency electrical signal. This signal is then converted into mechanical vibration by the ultrasonic transducer in the Z-axis ultrasonic module 19. The amplitude is amplified by an amplitude transformer and transmitted to the cutting tool or indenter head. This significantly shortens the transmission distance between the ultrasonic vibration generator in the Z-axis ultrasonic module 19 and the cutting tool, improving ultrasonic vibration transmission efficiency while avoiding transmission losses and vibration instability that might occur due to complex connection methods. The ultrasonic vibration generator is directly connected to the cutting tool or indenter head, ensuring that the generator's vibration is directly transmitted to the cutting tool. In this way, the cutting tool can vibrate in the Z-axis, thus ensuring that ultrasonic vibration machining can be achieved during processing or testing, resulting in improved cutting efficiency, reduced cutting force, and improved surface finish.

[0037] like Figure 3 In ultrasonic vibration testing, the Z-axis structure is crucial, requiring compliance with two conditions: loading and motion. The Z-axis servo motor 15 outputs torque, which is reduced in speed by gear 16 to drive the Z-axis ball screw 18. The ball screw 18 then converts the rotational motion into axial linear motion, enabling the Z-axis experimental platform, equipped with the Z-axis ultrasonic module 19, to move along the Z-axis on the Z-axis linear guide 17. The load is adjusted by the torque output from the Z-axis servo motor 15, and the magnitude of the output load is displayed by a pressure sensor 20, ultimately achieving the machining of the workpiece surface. The Z-axis can operate normally under heavy loads and achieve motion control. Therefore, this invention employs a novel transmission design, adding gear 16 between the Z-axis servo motor 15 and the Z-axis ball screw 18. The rotation of gear 16 is used to generate output torque, thereby increasing the output torque of the Z-axis. The Z-axis can withstand heavy loads. The Z-axis ball screw 18 accurately converts the rotational motion of the Z-axis servo motor 15 into linear motion, realizing Z-axis motion control. The addition of gear 16 increases torque, improves the transmission efficiency of the entire transmission system, and increases transmission stability.

[0038] like Figure 2 The Y-axis is driven by the balls on the screw between the screw and the nut of the Y-axis ball screw 5. When the Y-axis servo motor 3 drives the screw to rotate, the balls on the screw roll in the thread raceway, causing the moving parts connected to the nut to make linear motion, thus achieving the precise and stable displacement of the Y-axis displacement platform.

[0039] The X-axis of the parts fixture table 13 employs a transmission scheme combining a motor and a two-stage reducer. The X-axis is powered by an X-axis servo motor 10, which, in conjunction with the two-stage reducer 9, reduces the high speed of the X-axis servo motor 10 while increasing its output torque. The circular motion is then converted into linear motion via a rack and pinion transmission. Simultaneously, the motion trajectory is defined by the X-axis linear guide 11. The control system precisely controls the linear motion speed of the X-axis slide table 8 by adjusting the output speed of the X-axis servo motor 10, combined with the transmission ratio of the two-stage reducer 9 and the transmission characteristics of the rack and pinion, thereby achieving on-demand adjustment of the wiping speed and ensuring a smooth wiping process. A stable and reliable power source is provided for the X-axis, and the X-axis linear guide 11 supports its straight and smooth operation, confining the X-axis movement within its linear guide 11.

[0040] The ultrasonic vibration-assisted scratch test bench (scratch tester) provided by the present invention introduces ultrasonic vibration into scratch testing, improves the surface contact state of materials through high-frequency vibration, reduces friction interference, and enhances the sensitivity and accuracy of the test.

[0041] The ultrasonic vibration-assisted scratch test bench provided by this invention can apply vibration in different directions through different ultrasonic modules, such as in the axial, radial, and tangential directions. The ultrasonic vibration-assisted scratch test bench achieves vibration coupling in different directions through the X-axis ultrasonic module 12, Y-axis ultrasonic module 14, and Z-axis ultrasonic module 19 (XYZ three-axis independent ultrasonic vibration modules). The X-axis ultrasonic module 12 and Y-axis ultrasonic module 14 are directly connected to the workpiece fixture table 13 to drive the workpiece to perform horizontal vibration, while the Z-axis ultrasonic module 19 is directly connected to the tool / pressure head to achieve vertical vibration. The control system coordinates the vibration parameters of each axis to ensure synchronous triggering and parameter matching. It can flexibly combine XY-axis horizontal plane coupling, XZ / YZ-axis horizontal-vertical coupling, or XYZ three-axis spatial coupling to simulate complex vibration environments under different working conditions and analyze the mechanism of material removal.

[0042] Example 3, a scratching method for an ultrasonic vibration-assisted scratch testing bench includes: The X-axis transmission component is directly connected to the X-axis ultrasonic module 12 via a mechanical structure, which simplifies the vibration transmission path and allows the vibration energy to be directly transmitted to the workpiece, thereby controlling the speed of the scratch. The Y-axis transmission component is directly connected to the Y-axis ultrasonic module 14 via a mechanical structure, which simplifies the vibration transmission path and allows the vibration energy to be directly transmitted to the workpiece, enabling scratching at different positions on the Y-axis. The Z-axis transmission component is directly connected to the Z-axis ultrasonic module 19 via a mechanical structure, simplifying the vibration transmission path and allowing the vibration energy to be directly applied to the workpiece, thus completing the loading in the Z-axis direction.

[0043] In the above embodiments, the descriptions of each embodiment have different focuses. For parts that are not described in detail or recorded in a certain embodiment, please refer to the relevant descriptions of other embodiments.

[0044] 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 modifications, equivalent substitutions and improvements made by those skilled in the art within the scope of the technology disclosed in the present invention and within the spirit and principles of the present invention should be covered within the scope of protection of the present invention.

Claims

1. An ultrasonic vibration-assisted scratch testing bench, characterized in that, The test bench includes: The X-axis ultrasonic module (12) is directly connected by a mechanical structure, so that the energy of the vibration is directly transmitted to the X-axis transmission component of the workpiece, and the speed of the scratch is controlled by the X-axis transmission component. The Y-axis ultrasonic module (14) is directly connected by a mechanical structure, so that the energy of vibration is directly transmitted to the Y-axis transmission component of the workpiece, and the scratching at different positions on the Y-axis is achieved through the Y-axis transmission component. The Z-axis ultrasonic module (19) is directly connected by a mechanical structure, so that the vibration energy is directly loaded onto the Z-axis transmission component of the workpiece, and the loading in the Z-axis direction is completed through the Z-axis transmission component.

2. The ultrasonic vibration-assisted scratch testing bench according to claim 1, characterized in that, The X-axis transmission component is connected to the secondary reducer (9) via the X-axis servo motor (10) to provide power to the X-axis; The workpiece is fixed on the part fixture table (13). The secondary reducer (9) and the X-axis slider plate (8) convert the circular motion of the gear (16) into linear motion through the transmission of the gear (16) and rack. The X-axis slider plate (8) is connected to the X-axis linear guide (11) so that the X-axis moves on the linear guide, realizing the transmission in the X-axis direction and controlling the X-axis scratch length of the workpiece fixed on the part fixture table (13).

3. The ultrasonic vibration-assisted scratch testing bench according to claim 1, characterized in that, The Y-axis transmission component includes a Y-axis servo motor (3), which is connected to the Y-axis ball screw (5) via a coupling (4), driving the screw on the Y-axis ball screw (5) to rotate. The balls on the screw roll in the thread raceway, causing the moving component Y-axis slide (7) connected to the nut to move linearly on the Y-axis linear guide (6), completing the transmission in the Y-axis direction and realizing rubbing at different positions on the Y-axis.

4. The ultrasonic vibration-assisted scratch testing bench according to claim 1, characterized in that, The Z-axis transmission component transmits the output torque to the Z-axis ball screw (18) through the Z-axis servo motor (15) and gear (16). The Z-axis ball screw (18) converts the rotational motion of the Z-axis servo motor (15) into linear motion, so that the Z-axis ultrasonic module (19) moves along the Z-axis linear guide rail (17) to complete the loading in the Z-axis direction.

5. The ultrasonic vibration-assisted scratch testing bench according to claim 4, characterized in that, The loading force is monitored by a strain gauge pressure sensor (20) installed at the end of the mechanical structure and controlled in real time by a Z-axis servo motor (15).

6. The ultrasonic vibration-assisted scratch testing bench according to claim 1, characterized in that, Through the X-axis ultrasonic module (12), X-axis transmission component, Y-axis ultrasonic module (14), Y-axis transmission component, The Z-axis ultrasonic module (19) and any combination of Z-axis transmission components are used to simulate vibration environments under different working conditions by means of XY-axis horizontal plane coupling, XZ / YZ-axis horizontal-vertical coupling or XYZ three-axis spatial coupling.

7. The ultrasonic vibration-assisted scratch testing bench according to claim 1, characterized in that, The ultrasonic vibration-assisted scratch test bench also includes: a base shell (1) for supporting the X-axis ultrasonic module (12), X-axis transmission component, Y-axis ultrasonic module (14), Y-axis transmission component, Z-axis ultrasonic module (19), and Z-axis transmission component, and adjustable feet (2) at the bottom four corners of the base shell (1).

8. A scratching method for an ultrasonic vibration-assisted scratch testing bench, characterized in that, Implemented on the ultrasonic vibration-assisted scratch testing bench according to any one of claims 1 to 7, the method includes: The X-axis transmission component is directly connected to the X-axis ultrasonic module (12) by mechanical structure, which simplifies the vibration transmission path and allows the vibration energy to be directly transmitted to the workpiece, thereby controlling the speed of the scratch. By directly connecting the Y-axis transmission component and the Y-axis ultrasonic module (14) using a mechanical structure, the vibration transmission path is simplified, and the vibration energy is directly transmitted to the workpiece, thereby achieving scratching at different positions on the Y-axis. By directly connecting the Z-axis transmission component with the Z-axis ultrasonic module (19) using a mechanical structure, the vibration transmission path is simplified, and the vibration energy is directly applied to the workpiece to complete the loading in the Z-axis direction.

9. The scratching method of the ultrasonic vibration-assisted scratch testing bench according to claim 8, characterized in that, The X-axis ultrasonic module (12), Y-axis ultrasonic module (14), and Z-axis ultrasonic module (19) have a vibration frequency of 40kHz and an amplitude of 0-5μm. The amplitude is precisely controlled by adjusting the input voltage of the ultrasonic generator. The voltage can be flexibly increased or decreased according to actual needs to match the vibration intensity of different scenarios.

10. The scratching method of the ultrasonic vibration-assisted scratch testing bench according to claim 8, characterized in that, The ultrasonic vibration-assisted scratch test bench is used for scratching methods in the processing of difficult-to-machine materials, brittle and hard materials, and materials at the microscale.

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