A laser-preheated assisted ultrasonic-electrolytic composite turning method and apparatus

Abstract

This invention discloses a laser-preheated assisted ultrasonic-electrolytic composite turning method and apparatus, belonging to the field of metal cutting technology. It includes an ultrasonic-electrolytic composite cutting module, a laser module, a spindle module, a motion feed module, a bus control system, and an electrolyte delivery system. The spindle module is equipped with an independent spindle-side ultrasonic vibration system, driving high-frequency axial vibration of the workpiece. The tool-side ultrasonic-electrolytic composite cutting module is driven by a transducer to a variable amplitude rod, causing the surface-textured composite internal flow channel turning tool to generate high-frequency vibration. The vibration of the spindle and the tool is coordinated and controlled by the bus system. During machining, the laser module preheats and softens the area to be cut, reducing material hardness. The electrolyte is precisely delivered to the tool-chip and tool-workpiece contact areas through the internal flow channel, realizing multi-energy field composite machining of laser preheating, ultrasonic vibration-assisted cutting, electrolytic removal, and polishing. This effectively reduces cutting force and cutting temperature, suppresses tool wear, chipping, and surface scratches, and improves machining quality and efficiency.

Description

Technical Field

[0001] This invention belongs to the field of metal cutting technology, specifically, it relates to a laser preheating assisted ultrasonic-electrolytic composite turning method and apparatus, which is particularly suitable for efficient and precision machining of slender shaft parts made of difficult-to-machine conductive materials such as high-temperature alloys and metal matrix composites. Background Technology

[0002] Slender shafts (with a length-to-diameter ratio typically greater than 10) are widely used in aerospace, energy, and precision machinery fields, such as turbine shafts for aircraft engines and drive shafts for control rods in nuclear reactors. These parts are often manufactured using high-temperature alloys (such as Inconel 718 and GH4169 alloys), titanium alloys, or metal matrix composites (such as silicon carbide particle-reinforced SiCp / Al), possessing characteristics such as high strength, high hardness, and low thermal conductivity, making them typical difficult-to-machine materials. Traditional turning methods present the following problems: 1. High cutting force and severe tool wear: The high hardness and toughness of difficult-to-machine materials lead to a significant increase in cutting force, making the tool edge prone to chipping, adhesive wear and diffusion wear, resulting in extremely low tool life; 2. High cutting temperature makes it difficult to guarantee machining accuracy: Slender shafts have poor rigidity and are prone to bending deformation and vibration under large cutting forces. At the same time, the high temperature in the cutting zone will aggravate the thermal deformation of the workpiece, leading to loss of control over machining accuracy. 3. Poor surface integrity: Traditional cutting easily generates residual tensile stress, work-hardened layer and microcracks on the surface, which affects the fatigue life and service performance of the parts; 4. Difficulty in cooling and lubrication: The machining area of ​​slender shafts is narrow and long, making it difficult for conventional externally poured cutting fluids to effectively enter the tool-chip contact interface, resulting in limited cooling and lubrication effects.

[0003] To overcome the aforementioned challenges, various composite machining technologies have been proposed in the prior art. For example, laser-assisted machining utilizes laser preheating to soften the workpiece material, significantly reducing cutting forces (e.g., patent document CN121135476A discloses a multi-stage laser composite modification-assisted grinding method); ultrasonic vibration-assisted cutting uses high-frequency vibration to periodically separate the tool and chips, reducing friction and adhesion (e.g., patent document CN121776899A discloses an ultrasonic vibration-assisted milling method for Ti2AlNb materials); electrolytic machining can achieve stress-free and heat-affected zone material removal (e.g., patent document CN121820799A discloses an adjustable multi-electrode electrolytic turning apparatus and method). However, limitations still exist in the prior art: laser preheating during turning introduces a heat-affected zone with high thermal stress, easily leading to microcracks; ultrasonic vibration during turning has limited effectiveness on difficult-to-machine materials and increases tool chipping; electrolytic machining or laser-composite electrolytic machining of slender shafts has low efficiency. How to complement and synergize the advantages of multiple technologies, and resolve the contradiction between rigidity and precision in the machining of slender shafts, is a technical bottleneck that urgently needs to be overcome. Summary of the Invention

[0004] To address the problems of surface / subsurface residual stress, work-hardened layers, microcracks, and severe tool wear in existing technologies, this invention aims to provide a laser-preheated assisted ultrasonic-electrolytic composite turning method and apparatus. First, a laser module preheats and softens the area to be cut, reducing the difficulty of material cutting. Then, through an integrated module combining an ultrasonic-electrolytic composite tool holder and a surface-textured composite internal flow channel turning tool, electrolyte is precisely and efficiently delivered to the friction interface, achieving ultrasonic-electrolytic composite precision turning and polishing. This invention integrates softening, cutting, and polishing, effectively solving problems such as abnormal tool wear and chipping caused by high cutting temperatures and large cutting forces, and poor chip removal leading to scratches on machined surfaces, ultimately achieving high-quality and high-efficiency manufacturing of high-end parts.

[0005] The objective of this invention is achieved through the following technical solution: According to a first aspect of the present invention, a laser preheating-assisted ultrasonic-electrolytic composite turning device is provided, comprising: an ultrasonic-electrolytic composite cutting module, a laser module, a spindle module, a motion feed module, a bus control system, and an electrolyte delivery system; the ultrasonic-electrolytic composite cutting module includes an ultrasonic-electrolytic composite tool holder, a tool head, a tool post, and a surface-textured composite internal flow channel turning tool; the ultrasonic-electrolytic composite tool holder includes a transducer, an amplitude transformer, and a tool electrode, and its interior is provided with interconnected internal flow channels for the transducer and amplitude transformer, for delivering electrolyte while transmitting high-frequency vibration; the transducer is used to receive ultrasonic waves from an external ultrasonic generator. The system transmits high-frequency electrical signals of 30kHz to 40kHz and converts these signals into high-frequency mechanical vibrations along the axial direction of the amplitude transformer. The transducer and amplitude transformer form a tool-side ultrasonic vibration system. The surface-textured composite internal flow channel cutting tool and tool electrode are respectively mounted on the amplitude transformer. The surface-textured composite internal flow channel cutting tool includes a tool body and a tool insert, which has an internal flow channel. The rake face of the tool insert has a rake face microtexture, and the main flank face and secondary flank face have a main flank face microtexture and a secondary flank face microtexture, respectively. The rake face microtexture, the main flank face microtexture, and the secondary flank face microtexture all pass through the internal flow channel of the cutting tool. The microchannel is connected to the main flow channel inside the cutting tool; the flow channel inside the amplitude transformer is sealed and connected to the main flow channel inside the cutting tool; the laser module is located above the ultrasonic spindle and is used to preheat and soften the workpiece's cutting area using laser; the spindle module includes an ultrasonic spindle, which is used to mount the workpiece and drive its rotation, and is equipped with an independent spindle-side ultrasonic vibration system. The spindle-side ultrasonic vibration system is used to convert the high-frequency electrical signal (30kHz-40kHz) output from the external ultrasonic power supply into high-frequency mechanical vibration along the axis of the ultrasonic spindle, thereby driving the ultrasonic spindle and the workpiece to generate axial high-frequency vibration; the ultrasonic spindle and the amplitude transformer... The levers belong to the spindle module and the ultrasonic-electrolytic composite cutting module, respectively. They are not directly mechanically connected and are used to drive the workpiece and the surface-textured composite internal flow channel cutting tool to generate high-frequency vibrations, which are synchronized by the bus control system. The motion feed module drives the surface-textured composite internal flow channel cutting tool to feed relative to the workpiece. The tool electrode and the workpiece serve as the cathode and anode of the electrolytic machining, respectively, achieving electrolytic machining through the electrolyte output from the surface-textured composite internal flow channel cutting tool. The bus control system controls the coordinated operation of the ultrasonic-electrolytic composite cutting module, the laser module, the spindle module, the motion feed module, and the electrolyte delivery system.

[0006] Furthermore, the microtexture on the rake face, the microtexture on the main flank face, the microtexture on the secondary flank face, and the microchannel for internal flow in the cutting tool are designed differently: The outlet of the microchannel in the cutting tool corresponding to the rake face and the main flank face is the first aperture, and the scale configuration of the microtexture on the rake face and the microtexture on the main flank face is the first scale, which is used to deliver the electrolyte to the tool-chip contact area and the tool-workpiece contact area. The outlet of the microchannel in the tool corresponding to the secondary flank face is the second aperture, which is smaller than the first aperture. The microtexture of the secondary flank face is configured with the second scale, and its microtexture density is greater than that of the rake face and the main flank face. It is used to transport the electrolyte to the contact area between the secondary flank face and the workpiece.

[0007] Furthermore, the microtexture on the front face, the microtexture on the main flank face, and the microtexture on the secondary flank face include one or more combinations of micropores, microgrooves, or microtexture vein grooves, and their morphology is parallel grooves, grid-like, annular, or biomimetic vein-like; the width of the microtexture vein groove is 10μm to 250μm, and the depth is 10μm to 150μm.

[0008] Furthermore, the surface-textured composite internal flow channel turning tool includes a first surface-textured composite internal flow channel turning tool and / or a second surface-textured composite internal flow channel turning tool; the rake face of the first surface-textured composite internal flow channel turning tool adopts a surface texture formed by a combination of micro-textured vein grooves and micropores, and both the main flank face and the secondary flank face adopt a surface texture formed by a combination of micro-textured vein grooves and microgrooves; the rake face, main flank face, and secondary flank face of the second surface-textured composite internal flow channel turning tool all adopt a surface texture composed of micro-textured vein grooves, wherein the groove width of the micro-textured vein grooves is 10μm to 250μm, and the depth is 10μm to 150μm.

[0009] Furthermore, the ultrasonic-electrolytic composite tool holder also includes a fastening bolt with a quick-connect fitting and a sealing ring; the transducer and the amplitude transformer are fixedly connected by the fastening bolt with the quick-connect fitting, and the internal flow channel of the transducer and the internal flow channel of the amplitude transformer are connected through the internal channel of the fastening bolt with the quick-connect fitting; the internal flow channel of the amplitude transformer is sealed and connected to the main flow channel of the cutting tool through the sealing ring.

[0010] Furthermore, the laser module includes a laser, a reflector, and a focusing lens; the laser module is mounted above the ultrasonic spindle via a spindle clamp and is equipped with a servo push rod for adjusting the relative position of the laser spot and the workpiece, so that the laser spot is located in front of the surface texture composite internal flow channel cutting tool, and the center of the spot is aligned with the cutting edge.

[0011] Furthermore, a sliding electrode is fixedly installed at the front end of the ultrasonic spindle. The sliding electrode contains a copper ring for transmitting high-frequency drive electrical signals to the ultrasonic vibration system on the spindle side, an electrolytic anode electrode for connecting the workpiece as the electrolytic anode, and a shielding ring disposed between the copper ring and the electrolytic anode electrode. The copper ring is electrically connected to an external ultrasonic power supply. The high-frequency electrical signal output by the external ultrasonic power supply is transmitted to the ultrasonic vibration system on the spindle side via the copper ring. The ultrasonic vibration system on the spindle side converts the high-frequency electrical signal into axial high-frequency mechanical vibration, thereby driving the ultrasonic spindle and the workpiece to generate axial high-frequency vibration. The shielding ring is used to reduce electromagnetic interference between the ultrasonic drive signal and the electrolytic anode electrical signal.

[0012] Furthermore, the laser preheating assisted ultrasonic-electrolytic composite turning device also includes an ultrasonic-circulating electrolytic composite tool holder; the ultrasonic-circulating electrolytic composite tool holder has an internal channel for circulating electrolyte inlet and an internal channel for circulating electrolyte outlet, and the transducer has an internal channel for circulating electrolyte inlet and an internal channel for circulating electrolyte outlet; the internal channel for circulating electrolyte inlet, the internal channel for circulating electrolyte outlet, and the internal main channel for the tool inside the second surface texture composite internal channel together constitute the electrolyte circulation channel.

[0013] According to a second aspect of the present invention, a laser preheating-assisted ultrasonic-electrolytic composite turning method is provided, which is implemented using the aforementioned laser preheating-assisted ultrasonic-electrolytic composite turning device, and includes the following steps: Step 1: Optimize the laser preheating parameters, ultrasonic vibration parameters, electrolytic machining parameters, and cutting parameters through finite element simulation to determine the process parameters; Step 2: Mount the workpiece on the ultrasonic spindle, mount the surface textured composite internal flow channel cutting tool on the ultrasonic-electrolytic composite tool holder, and adjust the relative position of the laser spot and the surface textured composite internal flow channel cutting tool. Step 3: Write the machining program, setting the spindle speed, laser power and start-up timing, ultrasonic vibration parameters, electrolysis voltage and electrolyte supply timing, and feed path; Step 4: Perform composite machining according to the following timing sequence via the bus control system: Start the spindle module to rotate the workpiece; The ultrasonic vibration system on the tool side and the ultrasonic vibration system on the spindle side are started respectively, so that the transducer drives the surface textured composite internal flow channel turning tool to generate high-frequency vibration through the amplitude transformer, and the ultrasonic spindle drives the workpiece to generate axial high-frequency vibration through its independent spindle-side ultrasonic vibration system. Start the electrolyte delivery system to deliver the electrolyte to the tip of the lathe tool via the ultrasonic-electrolysis composite tool holder; The laser module is activated to preheat the area of ​​the workpiece to be cut; The motion feed module is controlled to feed along a predetermined path to perform composite turning operations; After processing is completed, shut down the laser module, electrolyte delivery system, tool-side ultrasonic vibration system, spindle-side ultrasonic vibration system, and spindle module in sequence, and then return to the motion feed module.

[0014] Furthermore, in step 1, the matching relationship between laser power and feed rate is determined with the goal of achieving a surface temperature in the preheating zone that reduces the material's yield strength by 50%. With the dual objectives of minimizing the main cutting force and optimizing the surface quality, the response surface methodology is used to optimize the cutting speed, feed rate, depth of cut, ultrasonic amplitude, and electrolysis voltage. In step 4, the laser spot is located 1mm to 2mm in front of the cutting tool, and the center of the spot is aligned with the cutting edge; The workpiece rotation speed is 300 r / min to 3000 r / min, the ultrasonic vibration frequency is 30 kHz to 40 kHz, and the amplitude is 5 μm to 15 μm; the electrolyte is an aqueous solution of NaNO3; the ultrasonic vibration system on the tool side and the ultrasonic vibration system on the spindle side are synchronously controlled by the bus control system or controlled according to a set phase relationship; the electrolyte is an aqueous solution of NaNO3; the electrolyte delivery system is started 2 to 3 seconds before the laser module is started, so that the electrolyte flows stably before the laser module is turned on; after the laser module is started and stabilized for 1 to 2 seconds, the motion feed module is controlled to start feeding.

[0015] The beneficial effects of the present invention through the above design scheme are as follows: 1. Synergistic effect of multiple energy fields to significantly reduce cutting force: laser preheating reduces material hardness, ultrasonic vibration causes periodic separation of tool and chip to reduce friction, and electrolysis forms a lubricating film at the interface and assists in material removal. The combination of these three factors can reduce the main cutting force by more than 50%, effectively suppressing the bending deformation and vibration of slender shafts. 2. Electrolysis improves surface integrity: During the cutting process, the "on-demand" micro-electrolyte applied to the secondary flank face can remove the laser heat-affected zone, eliminate the work-hardened layer and microcracks, and form a compressive stress layer on the machined surface; the electrolysis of the rake face and the main flank face can assist in the removal of materials (such as burrs), and the electrolytic polishing effect of the secondary flank face can further reduce the surface roughness; 3. Electrolytic protection, precise cooling and lubrication, significantly extending tool life: The capillary delivery network composed of the internal channels of the turning tool (the main internal flow channel and the internal flow micro channel) and the surface texture can accurately deliver a small amount of electrolyte to the tool-chip contact area and the tool-workpiece contact area. This can effectively reduce the area of ​​the tool-chip adhesion zone and increase the area of ​​the tool-chip sliding zone. At the same time, it can achieve "on-demand supply" of electrolyte in the tool-chip sliding zone (differentiated aperture of the internal flow micro channel). Compared with traditional turning methods, the amount of cutting fluid used is reduced by more than 80%, and the tool wear rate (chip adhesion wear, etc.) is reduced by more than 60%. 4. Ultrasonic vibration enhances mass transfer and cavitation cleaning: The cavitation effect generated by ultrasonic vibration can remove the adhering substances on the tool surface and promote the flow and renewal of electrolyte in the surface texture, maintaining the stability of the machining process; 5. Especially suitable for slender shafts and difficult-to-machine materials: By reducing cutting force and heat input, it effectively solves the problems of poor rigidity, easy deformation and easy vibration of slender shafts, and can realize efficient and precise machining of high-temperature alloy slender shafts with a length-to-diameter ratio of 15 or more. Attached Figure Description

[0016] The accompanying drawings, which are included to provide a further understanding of the invention and form part of this application, illustrate exemplary embodiments of the invention and are used to understand the invention. They do not constitute an improper limitation of the invention. In the drawings: Figure 1 This is a schematic diagram of the structure of the laser preheating assisted ultrasonic-electrolytic composite turning device in an embodiment of the present invention; Figure 2 This is a schematic diagram of the ultrasonic-electrolytic composite cutting module and the motion feed module in an embodiment of the present invention; Figure 3 This is a schematic diagram of the laser module and spindle module in an embodiment of the present invention; Figure 4 This is a schematic diagram of the ultrasonic-electrolytic composite tool holder and surface texture composite internal flow channel turning tool structure in an embodiment of the present invention; Figure 5 This is a partially enlarged schematic diagram of the surface-textured composite internal flow channel turning tool mounted on an ultrasonic-electrolytic composite tool holder in an embodiment of the present invention; Figure 6 This is a schematic diagram of the cutting tool insert structure of the first surface textured composite internal flow channel cutting tool in an embodiment of the present invention; Figure 7 This is a schematic diagram of the second surface texture composite internal flow channel cutting tool structure in an embodiment of the present invention; Figure 8 This is a schematic diagram of the ultrasonic-cyclic electrolytic composite tool holder and the second surface texture composite internal flow channel turning tool assembly in an embodiment of the present invention; Figure 9 This is a mesh generation diagram of the second surface texture composite internal flow channel cutting tool in an embodiment of the present invention; Figure 10 This is a mesh division diagram of the main internal flow channel and the micro internal flow channel of the cutting tool tip region in the second surface texture composite internal flow channel embodiment of the present invention; Figure 11 This is a simulation diagram of the internal electrolyte flow velocity distribution of the second surface textured composite internal flow channel cutting tool in this embodiment of the invention (the inlet flow velocity is set to 1 m / s, and the highest flow velocity in the outlet region reaches 13.52 m / s). Figure 12This is a simulation diagram of the local electrolyte flow velocity in the tip region of the second surface textured composite internal flow channel cutting tool in this embodiment of the invention (inlet velocity 1 m / s; wherein, the highest flow velocity at the first aperture outlet is 13.52 m / s, and the highest flow velocity at the second aperture outlet is 6.76 m / s). Figure 13 This is a simulation diagram of the internal electrolyte flow velocity distribution of the second surface textured composite internal flow channel cutting tool in this embodiment of the invention (the inlet flow velocity is set to 3 m / s, and the highest flow velocity in the outlet region can reach 37.3 m / s). Figure 14 This is a simulation diagram of the local electrolyte flow velocity in the tip region of the second surface textured composite internal flow channel cutting tool in this embodiment of the invention (inlet velocity 3 m / s; wherein, the highest flow velocity at the first aperture outlet is 37.3 m / s, and the highest flow velocity at the second aperture outlet is 19.8 m / s). Figure 15 This is a simulation diagram of the temperature field in the tip region of the second surface textured composite internal flow channel cutting tool in the embodiment of the present invention (the highest temperature at the tip reaches 524°C under conditions without electrolyte). Figure 16 This is a simulation diagram of the temperature field in the tip region of the second surface textured composite internal flow channel cutting tool in this embodiment of the invention under the condition of electrolyte introduction (inlet flow velocity 1 m / s, maximum flow velocity at the first aperture outlet 13.52 m / s, maximum flow velocity at the second aperture outlet 6.76 m / s; the highest temperature at the tool tip drops to 260℃). Figure 17 This is a simulation diagram of the temperature field in the tip region of the second surface textured composite internal flow channel cutting tool in the embodiment of the present invention under the condition of electrolyte introduction (inlet flow velocity 3m / s, highest flow velocity at the first aperture outlet 37.3m / s, highest flow velocity at the second aperture outlet 19.8m / s; the highest temperature at the tool tip is further reduced to 208℃).

[0017] The markings in the diagram are as follows: 1-Ultrasonic spindle; 2-Laser; 3-Servo push rod; 4-Sliding electrode; 5-Reflector; 6-Ultrasonic-electrolytic composite tool holder; 7-Z-axis slide; 8-Tool post; 9-X-axis slide; 10-Bed; 11-First surface textured composite internal flow channel turning tool; 12-Tool head; 13-Ultrasonic-electrolytic composite tool holder fixture; 14-Tool electrode; 15-Workpiece; 16-Focusing lens; 17-Spindle fixture; 18-Workpiece fixture; 19-Fasting bolt with quick-connect coupling; 20-Transducer; 21-Amplitude rod; 22-Amplitude rod internal flow channel; 2 3-Transducer internal flow channel; 24-Sealing ring; 25-Main flow channel of the cutting tool; 26-Cutting tool body; 27-Cutting tool insert; 28-Microtexture of the rake face; 29-Microtexture of the main flank face; 30-Microchannel of the cutting tool; 31-Microtexture vein groove; 32-Cutting tool with second surface texture composite internal flow channel; 33-Sealing port; 34-Electrolyte; 35-Circulating electrolyte outlet; 36-Circulating electrolyte drain internal flow channel; 37-Circulating electrolyte inlet internal flow channel; 38-Circulating electrolyte inlet; 39-Ultrasonic-circulating electrolysis composite tool holder; 40-Microtexture of the secondary flank face. Detailed Implementation

[0018] To make the objectives, features, and advantages of this invention more apparent and understandable, the technical solutions of this invention will be clearly and completely described below with reference to the accompanying drawings of the embodiments. Obviously, this invention is not limited to the following embodiments, and specific implementation methods can be determined according to the technical solutions of this invention and actual circumstances. To avoid obscuring the essence of this invention, well-known methods, processes, flows, components, and circuits are not described in detail.

[0019] like Figures 1 to 8 As shown, the laser preheating assisted ultrasonic-electrolytic composite turning device in this embodiment includes an ultrasonic-electrolytic composite cutting module, a laser module, a spindle module, a motion feed module, a bed 10, a bus control system, and an electrolyte delivery system. The ultrasonic-electrolytic composite cutting module, laser module, spindle module, and motion feed module are all fixedly mounted on the bed 10.

[0020] The ultrasonic-electrolytic composite cutting module includes an ultrasonic-electrolytic composite tool holder 6, a tool head 12, an ultrasonic-electrolytic composite tool holder fixture 13, a tool post 8, a first surface texture composite internal flow channel turning tool 11, a second surface texture composite internal flow channel turning tool 32, and an ultrasonic-cyclic electrolytic composite tool holder 39. The ultrasonic-electrolytic composite tool holder 6 includes a fastening bolt 19 with a quick-connect connector, a transducer 20, an amplitude transformer 21, a tool electrode 14, and a sealing ring 24. The first surface texture composite internal flow channel turning tool 11 consists of a tool base 26 and a tool insert 27. The laser module includes a laser 2, a servo push rod 3, a reflector 5, and a focusing lens 16. The spindle module includes an ultrasonic spindle 1, a sliding electrode 4, a workpiece 15, a spindle fixture 17, and a workpiece fixture 18. The motion feed module includes a Z-axis slide 7 and an X-axis slide 9. The ultrasonic-electrolytic composite tool holder 6 is fixedly connected to the transducer 20 and the amplitude transformer 21 by fastening bolts 19 with quick-connect fittings. Internally, it forms an inner flow channel 23 in the transducer and an inner flow channel 22 in the amplitude transformer, connected by the fastening bolts 19 with quick-connect fittings. This allows the amplitude transformer 21 to transmit high-frequency vibrations to the tool side while simultaneously delivering electrolyte 34 to the front end of the amplitude transformer 21. The ultrasonic-electrolytic composite tool holder 6 is fixedly mounted on the tool disc 12 and the tool holder 8 via an ultrasonic-electrolytic composite tool holder clamp 13. The tool holder 8 is fixedly mounted on the X-axis slide 9 via a Z-axis slide 7, controlling the tool feed to cut and remove material. A tool electrode 14 and a first surface textured composite inner flow channel cutting tool 11 are bolted onto the amplitude transformer 21. The inner flow channel 22 of the amplitude transformer is connected to the main inner flow channel 25 of the cutting tool via a sealing ring 24, allowing electrolyte 34 to flow from the inner flow channel 22 of the amplitude transformer to the main inner flow channel 25 of the cutting tool. The first surface textured composite internal flow channel turning tool 11 is formed by welding the turning tool base 26 and the turning tool insert 27 together; the turning tool base 26 and the internal flow channel of the turning tool insert 27 together form the turning tool internal flow main channel 25. The turning tool insert 27 has a rake face microtexture 28 (including micro-holes, micro-grooves or micro-texture vein grooves 31 and their combinations, with the shape of parallel grooves, mesh, ring or biomimetic veins) on the rake face, and a main flank face microtexture 29 and a secondary flank face microtexture 40 (also including micro-holes, micro-grooves or micro-texture vein grooves 31 and their combinations, with the shape of parallel grooves, mesh, ring or biomimetic veins) on the main flank face and the secondary flank face, respectively, and is connected to the turning tool internal flow main channel 25 through the turning tool internal flow microchannel 30. The rake face microtexture 28, the main flank face microtexture 29, the secondary flank face microtexture 40, and the interconnected internal flow microchannel 30 of the cutting tool adopt a differentiated design. The capillary delivery network formed by them can accurately deliver a small amount of electrolyte 34 to the tool-chip contact area and the tool-workpiece contact area. The groove width of the microtexture vein groove 31 ranges from 10μm to 250μm, and the depth ranges from μm to 150μm.

[0021] The rake face microtexture 28, the main flank face microtexture 29, the secondary flank face microtexture 40, and the connected internal flow microchannel 30 of the cutting tool insert 27 adopt differentiated designs: The outlet of the microchannel 30 in the tool inlet of the rake face and the main flank face is the first aperture, which serves as the main channel for the electrolyte 34 to flow out, providing sufficient electrolyte medium and accurately delivering the electrolyte 34 to the rake face-workpiece contact area and the main flank face-workpiece contact area, reducing the tool-chip adhesion area, thereby increasing the tool-chip sliding area, and forming a continuous electrolyte fluid film between the tool and the chip to cover the tool-chip contact area, achieving high-efficiency, low-damage, and high-precision turning (electrolysis-assisted material removal, improving turning efficiency and inhibiting damage formation), while also providing cooling and lubrication effects for the rake face and the main flank face; The outlet of the microchannel 30 in the tool corresponding to the secondary flank face is the second aperture. Its microtexture density is greater than that of the microtexture 28 on the rake face and the microtexture 29 on the main flank face. It is used to achieve micro-lubrication and electropolishing, and to precisely deliver the electrolyte 34 to the contact area between the secondary flank face and the workpiece. While ensuring the electropolishing effect, it reduces the amount of electrolyte 34 used, and also provides a lubrication effect, thereby improving the quality of the machined surface.

[0022] Furthermore, the ultrasonic-electrolytic composite tool holder 6 is a tool-side ultrasonic vibration transmission component. Under the control of the bus control system, it can transmit the high-frequency vibration generated by the transducer 20 to the tip of the first surface texture composite internal flow channel turning tool 11 (the tip of the turning tool insert 27) via the amplitude transformer 21. At the same time, in conjunction with the differentiated design of the rake face microtexture 28, the main flank face microtexture 29, the secondary flank face microtexture 40, and the interconnected internal flow microchannels 30 of the turning tool, it forms ultrasonic vibration enhanced mass transfer and cavitation cleaning, which can remove the adhering substances on the tool surface and promote the flow and renewal of the electrolyte 34 in the surface texture, maintaining the stability of the machining process.

[0023] Furthermore, the second surface texture composite internal flow channel cutting tool 32 is another surface composite texture of the first surface texture composite internal flow channel cutting tool 11 combined with the internal flow microchannel 30 structure. The rake face of the first surface texture composite internal flow channel cutting tool 11 is a surface texture formed by microtextured vein grooves and micropores and is connected to the internal flow microchannel 30. The flank face (flank face includes main flank face and secondary flank face) is a surface texture formed by microtextured vein grooves and microgrooves and is connected to the internal flow microchannel 30. The rake face and flank face (flank face includes main flank face and secondary flank face) of the second surface texture composite internal flow channel cutting tool 32 are both surface textures composed of microtextured vein grooves and are connected to the internal flow microchannel 30.

[0024] Furthermore, the ultrasonic-circulating electrolytic composite tool holder 39 is a differentiated structural design of the main internal flow channel 25 of the ultrasonic-circulating electrolytic composite tool holder 6. The ultrasonic-circulating electrolytic composite tool holder 39 has differentiated internal flow channels (circulating electrolyte discharge internal flow channel 36 and circulating electrolyte inlet internal flow channel 37) which together with the differentiated main internal flow channel 25 structure of the tool inside the second surface texture composite internal flow channel tool 32 form an electrolyte circulation channel; the transducer 20 has circulating electrolyte inlet and outlet (circulating electrolyte outlet 35 and circulating electrolyte inlet 38), which can be connected to the G1 / 8 quick connector to input and output electrolyte 34. The transducer 20 and the amplitude transformer 21 are internally provided with corresponding inlet and outlet liquid channels (circulating electrolyte outlet channel 36 and circulating electrolyte inlet channel 37), which can form a circulation channel with the tool 32 with the second surface texture composite inner flow channel and the tool inner flow main channel 25. The diameter of the inner flow channel connecting the transducer 20 and the amplitude transformer 21 is 2mm to 6mm, and the diameter of the inner flow channel connecting the amplitude transformer 21 and the tool 32 with the second surface texture composite inner flow channel is 1.5mm to 2mm. The internal flow main channel 25 of the composite internal flow channel turning tool 32 is designed with differentiated aperture sizes: the internal flow main channel 25 parallel to the main flank face and the secondary flank face has an aperture of 0.1mm to 0.4mm, and the internal flow main channel 25 on the side of the secondary flank face has an aperture of 0.4mm to 0.8mm. While ensuring the circulation of electrolyte 34, it can make the electrolyte 34 flowing through the rake face and the main / secondary flank face have a high and controllable flow rate, ensuring the internal circulation cooling efficiency and ensuring that the flow distribution of each outlet meets the design requirements.

[0025] The laser module is mounted directly above the ultrasonic spindle 1 via the spindle clamp 17. The relative positions of the reflector 5 and focusing lens 16 fixed at its front end and the workpiece 15 mounted on the ultrasonic spindle 1 by the workpiece clamp 18 are changed by the servo push rod 3. When the ultrasonic spindle 1 rotates, the laser preheating softening of the area to be cut on the surface of the workpiece 15 can be achieved, reducing the difficulty of material cutting.

[0026] A sliding electrode 4 is fixedly mounted at the front end of the ultrasonic spindle 1. The electrode contains a copper ring, an electrolytic anode electrode, and a shielding ring positioned between the copper ring and the electrolytic anode electrode. The copper ring, acting as a rotating conductive transmission component for the high-frequency drive signal, is electrically connected to an external ultrasonic power supply. It transmits the high-frequency electrical signal output by the ultrasonic power supply to the spindle-side ultrasonic vibration system configured on the ultrasonic spindle 1. The spindle-side ultrasonic vibration system converts the high-frequency electrical signal into high-frequency mechanical vibration along the spindle axis, thereby driving the ultrasonic spindle 1 and the workpiece 15 it holds to generate axial high-frequency vibration. The electrolytic anode electrode connects to the workpiece 15, making the workpiece 15 the anode for electrolytic machining. The shielding ring, located between the copper ring and the electrolytic anode electrode, reduces electromagnetic interference between the ultrasonic drive signal and the electrolytic anode electrical signal.

[0027] It should be noted that the ultrasonic spindle 1 and the amplitude transformer 21 are not directly mechanically connected. The ultrasonic spindle 1 belongs to the spindle module, and its high-frequency vibration is generated by the ultrasonic vibration system on the spindle side and transmitted to the workpiece 15; the amplitude transformer 21 belongs to the ultrasonic-electrolytic composite tool holder 6, and its high-frequency vibration is generated by the transducer 20 and transmitted to the cutting tool. The two ultrasonic vibration links are coordinated and controlled in terms of start / stop timing, frequency, or phase relationship through a bus control system, rather than transmitting vibration to each other through a rigid connection structure.

[0028] Furthermore, the electrolytic anode electrode (connected to the workpiece 15) built into the sliding electrode 4 and the tool electrode 14 (electrolytic cathode electrode connected to the first surface texture composite internal flow channel cutting tool 11) mounted on the amplitude transformer 21 by bolts use the electrolyte 34 flowing out of the first surface texture composite internal flow channel cutting tool 11 as a medium to achieve precision electrolytic machining of the workpiece 15.

[0029] Example 1: Structural design and fabrication of a surface-textured composite internal flow channel cutting tool: This embodiment provides a specific implementation of a surface-textured composite internal flow channel turning tool. See also... Figure 7 The second surface textured composite internal flow channel turning tool 32 uses ultra-fine grain cemented carbide as the tool material, with an average grain size of 0.5μm to 0.8μm, ensuring that the tool has sufficient high-temperature hardness and bending strength. The insert model is CCGW060200, with an 80° rhomboid shape, no rounded tip, a rake angle of +6° to +8°, ​​and a clearance angle of 7°.

[0030] The main internal flow channel 25 of the second surface-textured composite internal flow channel turning tool 32 is fabricated using micro-electrical discharge machining (EDM). The rake face microtexture 28, main flank face microtexture 29, secondary flank face microtexture 40, and internal flow microchannel 30 on the second surface-textured composite internal flow channel turning tool 32 are fabricated using femtosecond laser processing technology. The processing area is determined through finite element simulation, and the specific steps include: First, a thermo-mechanical coupling turning model of the tool and workpiece is established. Based on actual cutting parameters (such as cutting speed 47 m / min, depth of cut 0.5 mm, and feed rate 0.15 mm / r), transient dynamic analysis is performed to obtain equivalent stress distribution cloud maps, temperature distribution cloud maps, and contact pressure distribution cloud maps on the tool's rake face, main flank face, and secondary flank face during the cutting process. Then, the continuous region with equivalent stress values ​​higher than 100 MPa and temperature values ​​higher than 40℃ is defined as the rake face microtextured machining region; the strip-shaped regions on the main flank face and secondary flank face adjacent to the cutting edge and with contact pressure higher than 20 MPa are defined as the main flank face and secondary flank face microtextured machining regions.

[0031] First, micro-electro-discharge machining (EDM) is used to machine three interconnected internal flow channels 25 on the side of the second-surface textured composite internal flow channel turning tool 32, with a hole diameter of 0.6 mm to 1.5 mm. Then, the sealing port 33 is sealed by welding or sealing bolts to prevent the electrolyte 34 from flowing out from the side. Next, femtosecond laser machining is used to machine the micro-textured vein grooves 31 and the internal flow microchannels 30 of the second-surface textured composite internal flow channel turning tool 32. Within the machining area of ​​the micro-textured 28 on the rake face, micro-textured vein grooves 31 with a depth of 30 μm to 50 μm and a width of 50 μm to 80 μm are prepared. The starting end of the groove is connected to the outlet of the internal flow microchannel 30 on the rake face, and the direction of the groove is consistent with the chip flow direction. The direction of the internal flow microchannel 30 is opposite to the chip flow direction to facilitate the guidance and chip removal of the electrolyte 34. Within the machining areas of the main flank face microtexture 29 and the secondary flank face microtexture 40, microtextured grooves 31 with a depth of 20μm to 40μm and a width of 40μm to 60μm are prepared. These microtextured grooves 31 are also connected to the outlets of the internal flow microchannels 30 of the cutting tool on the main flank face and the secondary flank face, ensuring that the electrolyte 34 can flow out directionally from the internal flow microchannels 30 of the cutting tool through the microtextured grooves 31.

[0032] Example 2: Differentiated internal flow channel structure design: This embodiment details the design method for the differentiated internal flow channels of the second-surface textured composite internal flow channel turning tool 32. See also... Figure 8 The second surface textured composite internal flow channel cutting tool 32 has differentiated electrolyte flow channels inside: The outlet of the microchannel 30 in the rake face and main flank face is designed as the first aperture, with an aperture of 0.5mm to 0.8mm. This serves as the main channel through which the electrolyte 34 flows, providing sufficient cooling, lubrication, and electrolytic medium. The first aperture outlet on the rake face is located at the center of the microtexture 28 region on the rake face, ensuring that a large amount of electrolyte 34 can flow out from the first aperture. This electrolyte then covers the entire tool-chip contact area via the microtexture grooves 31, forming a continuous fluid film that effectively removes frictional heat and reduces the coefficient of friction, while also assisting in the electrolytic removal of chips.

[0033] The outlet of the internal flow microchannel 30 on the secondary flank face is designed as a second aperture, with an aperture of 0.1mm to 0.4mm, for achieving micro-lubrication and electropolishing. These second aperture outlets are located at key positions in the microtexture 40 region of the secondary flank face (typically distributed along the wear zone), ensuring that a small but precise amount of electrolyte 34 can be delivered to the main flank face and the secondary flank face-workpiece contact area, significantly reducing the amount of electrolyte 34 used while maintaining the micro-lubrication and electropolishing effect.

[0034] The main internal flow channel 25 of the second surface textured composite internal flow channel turning tool 32 has an aperture of 0.6mm to 1.5mm. Its flow channel inlet is located on the side wing surface of the cutting tool and is connected to the sealing ring 24. The main internal flow channel 25 of the turning tool adopts a branch structure, which splits the flow from the main inlet to the rake face, the main flank face turning tool internal flow microchannel 30 (first aperture), and the secondary flank face turning tool internal flow microchannel 30 (second aperture), to ensure that the flow distribution of each outlet meets the design requirements.

[0035] Example 3: Simulation analysis of electrolyte flow characteristics and cooling effect in internal flow channels: Based on the structural design of Example 2, this embodiment uses computational fluid dynamics (CFD) to simulate and analyze the internal flow field and temperature field of the second surface textured composite internal flow channel cutting tool 32, in order to verify the effectiveness of the differentiated internal flow channel design.

[0036] 1. Simulation model establishment: A fluid-structure interaction (FSI) simulation model was established using ANSYS Fluent software. First, fluid domain modeling and mesh generation were performed: the microchannel lathe tool model was imported into the ANSYS DesignModeler module, and Boolean operations were used to extract the fluid domain within the microchannel, achieving effective separation between the solid tool domain and the fluid domain.

[0037] The mesh generation employs a regional fine-grained control strategy: the mesh size for the tool solid domain is set to 0.1 mm; to accurately characterize the confined flow and heat transfer behavior within the microchannel 30 inside the cutting tool, the core flow channel region of the fluid domain is locally refined with a mesh size of 0.05 mm; simultaneously, boundary layer expansion layers are set at the inlet, outlet, and wall of the microchannel 30 inside the cutting tool to increase the near-wall mesh density, accurately capture the wall boundary layer flow, inlet and outlet flow separation, and convective heat transfer characteristics, reduce the calculation errors of wall shear stress and heat transfer coefficient, and ensure the reliability of the flow and heat transfer simulation within the microchannel 30 inside the cutting tool. The mesh generation results are as follows: Figure 9 , Figure 10 As shown.

[0038] 2. Boundary conditions and solver settings: Further configure the inlet and outlet boundaries, wall conditions, and solution model of the fluid domain to construct a complete thermo-fluid-structure interaction simulation system: Inlet boundary: The inlet of the microchannel 30 in the cutting tool adopts the velocity inlet boundary condition, and the inlet velocity is set to 1m / s and 3m / s respectively to simulate the flow characteristics under different electrolyte supply flow rates 34.

[0039] Outlet boundary: All outlets are set to pressure outlet boundary conditions, and the outlet pressure is set to standard atmospheric pressure (101325Pa) to realistically reproduce the discharge environment of electrolyte 34.

[0040] Wall conditions: The interface between the fluid domain and the tool solid domain is set as a fluid-structure interaction wall, a no-slip velocity condition is adopted, and the energy equation is activated to realize the heat transfer between the tool wall and the electrolyte 34.

[0041] Turbulence Model: Considering the restricted turbulent flow characteristics of the electrolyte 34 in the microchannel 30 of the cutting tool, the standard k-ε turbulence model is selected to describe the turbulent behavior of the flow field. This model can effectively predict the separation of the wall boundary layer flow and the inlet and outlet flow, and is suitable for the complex flow and heat transfer scenarios in the microchannel 30 of the cutting tool.

[0042] Solution algorithm: The SIMPLE algorithm is used for pressure-velocity coupling calculation.

[0043] 3. Simulation Results and Analysis: (1) Flow field characteristic analysis When the inlet velocity is 1 m / s ( Figure 11 , Figure 12 The electrolyte 34, after being diverted through the main flow channel 25 inside the cutting tool, is ejected from the first aperture outlet on the rake face and main flank face, with a maximum flow velocity of 13.52 m / s; it is ejected from the second aperture outlet on the secondary flank face, with a maximum flow velocity of approximately 6.76 m / s. The flow velocity at the first aperture outlet is approximately twice that at the second aperture outlet, demonstrating the effect of the differentiated flow distribution design.

[0044] When the inlet velocity increases to 3 m / s ( Figure 13 , Figure 14 The highest flow velocity at the outlet of the first aperture can reach 37.3 m / s, and the highest flow velocity at the outlet of the second aperture can reach 19.8 m / s. The results show that, regardless of whether the flow rate is high or low, the first aperture of both the rake face and the main flank face can obtain sufficient high-speed electrolyte 34 to form a continuous fluid film to cover the tool-chip contact area; while the second aperture of the secondary flank face delivers electrolyte 34 at a lower but sufficient speed, achieving micro-lubrication and electropolishing.

[0045] (2) Temperature field analysis: Without electrolyte 34 ( Figure 15 During continuous cutting, the cutting tip area generates a large amount of heat due to friction and material deformation, with temperatures reaching up to 524°C. High temperatures accelerate tool wear and deteriorate surface quality.

[0046] Under the condition of introducing electrolyte 34 (inlet velocity 1 m / s) Figure 16 The highest temperature in the blade tip region dropped to approximately 260℃, a decrease of over 50%. When the inlet velocity increased to 3 m / s ( Figure 17The highest temperature in the cutting tip region was further reduced to approximately 208°C, a decrease of over 60%. Simulation results show that the differentiated internal flow channel structure designed in this invention can accurately deliver the electrolyte 34 to the high-temperature region, significantly reducing the cutting zone temperature through forced convection heat transfer.

[0047] 4. Simulation conclusions: This embodiment verifies the effectiveness of the differentiated internal flow channel design inside the second surface texture composite internal flow channel cutting tool 32 through CFD simulation: The first aperture (rake face, main flank face) can obtain electrolyte 34 with a high flow rate, forming a continuous fluid film to achieve efficient cooling, lubrication and electrolytic-assisted removal; The second aperture (secondary back face) delivers electrolyte 34 at a moderate flow rate to achieve micro-lubrication and electropolishing, while saving the amount of electrolyte 34 used. After the electrolyte 34 was introduced, the highest temperature in the blade tip area dropped from 524℃ to 208℃ (at an inlet velocity of 3 m / s), a decrease of more than 60%, proving that the structure has excellent cooling performance.

[0048] The simulation results provide a theoretical basis and parameter guidance for subsequent actual cutting experiments.

[0049] Example 4: Electrolyte circulation and differentiated design of electrolyte circulation channels: This embodiment details the design method for the differentiated electrolyte circulation channel between the ultrasonic-circulating electrolytic composite tool holder 39 and the second surface textured composite internal flow channel of the lathe tool 32. See also... Figure 7 and Figure 8 The ultrasonic-circulating electrolysis composite tool holder 39 has an internal electrolyte circulation channel and a second surface texture composite internal flow channel. The cutting tool 32 has an internal electrolyte circulation channel and a differentiated flow channel. The transducer 20 is provided with circulating electrolyte inlets and outlets (circulating electrolyte outlet 35 and circulating electrolyte inlet 38), which can be connected to a G1 / 8 quick-connect connector for inputting and outputting electrolyte 34. The transducer 20 and the amplitude transformer 21 have corresponding internal flow channels for inlet and outlet electrolyte (circulating electrolyte outlet channel 36 and circulating electrolyte inlet channel 37), which can form a circulation channel with the internal flow main channel 25 of the cutting tool 32 with the second surface texture composite internal flow channel. The diameter of the internal flow channel connecting the transducer 20 and the amplitude transformer 21 is 2mm to 6mm, and the diameter of the internal flow channel connecting the amplitude transformer 21 and the cutting tool 32 with the second surface texture composite internal flow channel is 1.5mm to 2mm. The internal flow main channel 25 of the internal flow channel turning tool 32 is designed with differentiated aperture size: the internal flow main channel 25 parallel to the main flank face and the secondary flank face has a second aperture of 0.1mm to 0.4mm, and the internal flow main channel 25 on the side of the secondary flank face has a first aperture of 0.4mm to 0.8mm. While ensuring electrolyte circulation, it can make the electrolyte 34 flowing through the rake face, the main flank face and the secondary flank face have a high and controllable flow rate, ensure internal circulation cooling efficiency, and ensure that the flow distribution of each outlet meets the design requirements.

[0050] Example 5: Laser preheating assisted ultrasonic-electrolytic composite turning method: This embodiment provides a specific implementation of a laser preheating-assisted ultrasonic-electrolytic composite turning method. See also... Figure 1 The aforementioned laser preheating-assisted ultrasonic-electrolytic composite turning device includes the following steps, which are performed sequentially: Step 1: Simulation modeling and process parameter optimization: Laser heating simulation and ultrasonic-electrolytic composite cutting simulation were performed using ANSYS Workbench, Maxwell, and Fluent finite element simulation software. This provides guidance for setting parameters such as laser output power, electrolytic output voltage, vibration frequency, amplitude, spindle speed, feed rate, and depth of cut in the bus control system program, as well as for selecting the electrolyte type.

[0051] (1) Simulation of laser heating temperature field: A nonlinear heat conduction model of the workpiece material is established, considering the change of material thermal properties with temperature, and a moving Gaussian heat source is applied to simulate the laser preheating process. The temperature distribution of the preheating zone under different laser powers (300W~1500W), scanning speeds (matched with the feed speed), and spot diameters is obtained through simulation. Taking the temperature required for the surface temperature of the preheating zone to reach the material's yield strength by 50% (approximately 600℃~700℃) as the target, the matching relationship between laser power and feed speed is determined. The laser power is established. Feed rate With preheating temperature The multiple regression equation between them: ; Among them, the regression coefficient , , , , , The values ​​were obtained by fitting simulation data (the specific values ​​depend on the workpiece material). Taking GH4169 as an example, the preferred parameters are: laser power 800W, feed speed 0.08mm / r, and preheating temperature of approximately 650℃.

[0052] (2) Simulation of ultrasonic-electrolytic composite cutting process: A fluid-solid-electric multiphysics coupling model was established. An electrolyte flow model was established in Fluent, using the k-ε turbulence model. Boundary conditions for velocity inlet (electrolyte flow velocity 10-50 m / s) and pressure outlet were set, and the velocity distribution and pressure drop in the microtextured channel were calculated. An electric field model was established in Maxwell, and the Laplace equation was solved to obtain the current density distribution between the tool and the workpiece. The electrolysis voltage (6V-30V) was optimized based on a current density of not less than 0.5 A / cm². A tool vibration model was established in ANSYS Mechanical, and ultrasonic frequencies (20kHz-50kHz) and amplitudes (0-20μm) were applied to analyze the tool tip trajectory and stress distribution.

[0053] The main cutting force was established through orthogonal simulation experiments. Regression equation between the main process parameters: ; in: For cutting speed, For feed rate, To measure the amount of knife cuts on the back, This refers to the ultrasonic amplitude. Electrolysis voltage. Regression coefficient. , , , , , , , , , , Obtained by fitting simulation data.

[0054] With the dual objectives of minimizing cutting force and optimizing surface quality, the response surface methodology (RSM) is used to optimize parameters and determine the optimal range of process parameters.

[0055] Step 2: Device installation and tool setting: The workpiece 15 to be processed is mounted and fixed on the ultrasonic spindle 1, and the first surface textured composite internal flow channel turning tool 11 is fixedly mounted on the ultrasonic-electrolytic composite tool holder 6. The bus control system is turned on to control the Z-axis slide 7, X-axis slide 9, tool holder 8 and servo push rod 3. At the same time, the red light preview of the laser 2 is turned on, and the relative positions of the first surface textured composite internal flow channel turning tool 11, the laser spot and the workpiece 15 are adjusted so that the laser spot is located about 1mm to 2mm in front of the tool, and the center of the spot is aligned with the cutting edge.

[0056] Step 3: Programming the machining process: Based on the preferred process parameter range obtained in step 1, and in conjunction with specific processing requirements (material, dimensions, surface quality requirements), write the corresponding processing program. The program should include: spindle speed, laser power and activation sequence, ultrasonic vibration parameters (frequency, amplitude), electrolysis voltage and electrolyte supply sequence, Z-axis and X-axis feed paths and speeds, and the activation / deactivation sequence of each functional module.

[0057] Step 4: Composite processing execution: The machining program is started via a bus control system, with the following specific timing sequence: (1) Start the spindle module to make the workpiece 15 rotate at the set speed (usually 300r / min to 3000r / min). (2) Start the ultrasonic vibration system on the tool side and the ultrasonic vibration system on the spindle side respectively: the high-frequency vibration generated by the transducer 20 on the tool side is transmitted to the tip of the surface textured composite internal flow channel cutting tool through the amplitude transformer 21; the high-frequency electrical signal output by the external ultrasonic power supply is transmitted to the ultrasonic vibration system on the spindle side of the ultrasonic spindle 1 by the copper ring in the sliding electrode 4, thereby driving the ultrasonic spindle 1 and the workpiece 15 to generate axial high-frequency vibration (frequency 30kHz~40kHz, amplitude 5μm~15μm). (3) Open the electrolyte delivery system so that the electrolyte 34 (such as 5% NaNO3 aqueous solution) flows through the ultrasonic-electrolysis composite tool holder 6 to the tip outlet of the first surface textured composite internal flow channel cutting tool 11 and flows stably for about 2 to 3 seconds; (4) Turn on the laser module to preheat the area to be cut with the laser beam, and wait for the temperature to stabilize (about 1 to 2 seconds). (5) Control the Z-axis slide 7 and X-axis slide 9 to feed according to the predetermined program and start the compound turning process; (6) During the processing, the bus control system monitors the cutting force, temperature, current and other signals in real time, and makes adaptive adjustments according to the preset threshold (such as fine-tuning the feed speed or laser power when necessary). (7) After the workpiece 15 has been machined, turn off the laser module, ultrasonic-electrolytic composite cutting module and ultrasonic spindle 1 in sequence; (8) Finally, control the Z-axis slide 7 and X-axis slide 9 to return to the origin.

[0058] Step 5: Post-processing and inspection: After machining, remove workpiece 15 for cleaning and drying. Measure the surface roughness using a surface roughness meter, measure residual stress using X-ray diffraction, and observe the work-hardened layer thickness and microcracks using a metallographic microscope. If the requirements are met, machining is complete; otherwise, fine-tune the process parameters based on the test results and repeat the above steps.

[0059] Thus, a laser preheating-assisted ultrasonic-electrolytic composite turning method has been completed.

[0060] The above description is merely a preferred embodiment of the present invention and is not intended to limit the invention. Various modifications and variations can be made to the present invention by those skilled in the art. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the scope of protection of the present invention.

Claims

1. A laser preheating assisted ultrasonic-electrolytic combined turning processing device, characterized in that, include: The system comprises an ultrasonic-electrolytic composite cutting module, a laser module, a spindle module, a motion feed module, a bus control system, and an electrolyte delivery system. The ultrasonic-electrolytic composite cutting module includes an ultrasonic-electrolytic composite tool holder, a tool head, a tool post, and a surface-textured composite internal flow channel turning tool. The ultrasonic-electrolytic composite tool holder includes a transducer, an amplitude transformer, and a tool electrode. Internally, it has interconnected internal flow channels in the transducer and amplitude transformer for delivering electrolyte while transmitting high-frequency vibrations. The transducer receives 30kHz frequency ultrasonic waves transmitted from an external ultrasonic generator. A high-frequency electrical signal of Hz to 40kHz is used, which is converted into high-frequency mechanical vibration along the axis of the amplitude transformer. The transducer and the amplitude transformer form a tool-side ultrasonic vibration system. The surface-textured composite internal flow channel cutting tool and the tool electrode are respectively mounted on the amplitude transformer. The surface-textured composite internal flow channel cutting tool includes a cutting tool body and a cutting tool insert. It has an internal flow channel. The rake face of the cutting tool insert has a rake face microtexture. The main flank face and the secondary flank face have a main flank face microtexture and a secondary flank face microtexture, respectively. The rake face microtexture, Both the primary and secondary flank face microtextures are connected to the main internal flow channel of the cutting tool via internal flow microchannels; the amplitude transformer's internal flow channel is sealed and connected to the main internal flow channel of the cutting tool; the laser module is positioned above the ultrasonic spindle and is used for laser preheating and softening of the workpiece's cutting area; the spindle module includes an ultrasonic spindle, which is used to mount the workpiece and drive its rotation, and is equipped with an independent spindle-side ultrasonic vibration system, which is used to output a frequency of 30kHz to 40kHz from an external ultrasonic power supply. The high-frequency electrical signal is converted into high-frequency mechanical vibration along the axis of the ultrasonic spindle, thereby driving the ultrasonic spindle and the workpiece to generate axial high-frequency vibration; the motion feed module is used to drive the surface textured composite internal flow channel cutting tool to feed relative to the workpiece; the tool electrode and the workpiece serve as the cathode and anode of electrolytic machining, respectively, and electrolytic machining is achieved through the electrolyte output by the surface textured composite internal flow channel cutting tool; the bus control system is used to control the coordinated operation of the ultrasonic-electrolytic composite cutting module, the laser module, the spindle module, the motion feed module, and the electrolyte delivery system.

2. The laser preheating assisted ultrasonic-electrolytic composite turning apparatus according to claim 1, characterized in that, The microtexture on the rake face, the microtexture on the main flank face, the microtexture on the secondary flank face, and the microchannel for internal flow in the cutting tool are designed differently: The outlet of the microchannel in the cutting tool corresponding to the rake face and the main flank face is the first aperture, and the scale configuration of the microtexture on the rake face and the microtexture on the main flank face is the first scale, which is used to deliver the electrolyte to the tool-chip contact area and the tool-workpiece contact area. The outlet of the microchannel in the tool corresponding to the secondary flank face is the second aperture, which is smaller than the first aperture. The microtexture of the secondary flank face is configured with the second scale, and its microtexture density is greater than that of the rake face and the main flank face. It is used to transport the electrolyte to the contact area between the secondary flank face and the workpiece.

3. The laser preheating assisted ultrasonic-electrolytic composite turning apparatus according to claim 2, characterized in that, The microtexture on the front face, the microtexture on the main flank face, and the microtexture on the secondary flank face include one or more combinations of micropores, microgrooves, or microtexture vein grooves, and their morphology is parallel grooves, grid-like, annular, or biomimetic vein-like; the width of the microtexture vein groove is 10μm to 250μm, and the depth is 10μm to 150μm.

4. The laser preheating assisted ultrasonic-electrolytic composite turning apparatus according to claim 1, characterized in that, The surface-textured composite internal flow channel turning tool includes a first surface-textured composite internal flow channel turning tool and / or a second surface-textured composite internal flow channel turning tool; the rake face of the first surface-textured composite internal flow channel turning tool adopts a surface texture formed by a combination of micro-textured vein grooves and micro-holes, and both the main flank face and the secondary flank face adopt a surface texture formed by a combination of micro-textured vein grooves and micro-grooves; the rake face, main flank face, and secondary flank face of the second surface-textured composite internal flow channel turning tool all adopt a surface texture composed of micro-textured vein grooves, wherein the groove width of the micro-textured vein grooves is 10μm to 250μm and the depth is 10μm to 150μm.

5. The laser preheating assisted ultrasonic-electrolytic composite turning apparatus according to claim 1, characterized in that, The ultrasonic-electrolytic composite tool holder also includes a fastening bolt with a quick-connect fitting and a sealing ring; the transducer and the amplitude transformer are fixedly connected by the fastening bolt with the quick-connect fitting, and the internal flow channel of the transducer and the internal flow channel of the amplitude transformer are connected through the internal channel of the fastening bolt with the quick-connect fitting; the internal flow channel of the amplitude transformer is sealed and connected to the main flow channel of the cutting tool through the sealing ring.

6. The laser preheating assisted ultrasonic-electrolytic composite turning apparatus according to claim 1, characterized in that, The laser module includes a laser, a reflector, and a focusing lens. The laser module is mounted on top of the ultrasonic spindle via a spindle clamp and is equipped with a servo push rod for adjusting the relative position of the laser spot and the workpiece, so that the laser spot is located in front of the surface texture composite internal flow channel cutting tool and the center of the spot is aligned with the cutting edge.

7. The laser preheating assisted ultrasonic-electrolytic composite turning apparatus according to claim 1, characterized in that, A sliding electrode is fixedly installed at the front end of the ultrasonic spindle. The sliding electrode contains a copper ring for transmitting high-frequency drive electrical signals to the ultrasonic vibration system on the spindle side, an electrolytic anode electrode for connecting the workpiece as the electrolytic anode, and a shielding ring disposed between the copper ring and the electrolytic anode electrode. The copper ring is electrically connected to an external ultrasonic power supply. The high-frequency electrical signal output by the external ultrasonic power supply is transmitted to the ultrasonic vibration system on the spindle side via the copper ring. The ultrasonic vibration system on the spindle side converts the high-frequency electrical signal into axial high-frequency mechanical vibration, thereby driving the ultrasonic spindle and the workpiece to generate axial high-frequency vibration. The shielding ring is used to reduce electromagnetic interference between the ultrasonic drive signal and the electrolytic anode electrical signal.

8. The laser preheating assisted ultrasonic-electrolytic composite turning apparatus according to claim 1, characterized in that, The laser preheating-assisted ultrasonic-electrolytic composite turning device further includes an ultrasonic-circulating electrolytic composite tool holder; the ultrasonic-circulating electrolytic composite tool holder has an internal channel for circulating electrolyte inlet and an internal channel for circulating electrolyte outlet, and the transducer has an internal channel for circulating electrolyte inlet and an internal channel for circulating electrolyte outlet; the internal channel for circulating electrolyte inlet, the internal channel for circulating electrolyte outlet, and the internal main channel for the tool inside the second surface texture composite internal channel together constitute the electrolyte circulation channel.

9. A laser-preheated assisted ultrasonic-electrolytic composite turning method, characterized in that, The laser preheating-assisted ultrasonic-electrolytic composite turning apparatus according to any one of claims 1 to 8 includes the following steps: Step 1: Optimize the laser preheating parameters, ultrasonic vibration parameters, electrolytic machining parameters, and cutting parameters through finite element simulation to determine the process parameters; Step 2: Mount the workpiece on the ultrasonic spindle, mount the surface textured composite internal flow channel cutting tool on the ultrasonic-electrolytic composite tool holder, and adjust the relative position of the laser spot and the surface textured composite internal flow channel cutting tool. Step 3: Write the machining program, setting the spindle speed, laser power and start-up timing, ultrasonic vibration parameters, electrolysis voltage and electrolyte supply timing, and feed path; Step 4: Perform composite machining according to the following timing sequence via the bus control system: Start the spindle module to rotate the workpiece; The ultrasonic vibration system on the tool side and the ultrasonic vibration system on the spindle side are started respectively, so that the transducer drives the surface textured composite internal flow channel turning tool to generate high-frequency vibration through the amplitude transformer, and the ultrasonic spindle drives the workpiece to generate axial high-frequency vibration through its independent spindle-side ultrasonic vibration system. Start the electrolyte delivery system to deliver the electrolyte to the tip of the lathe tool via the ultrasonic-electrolysis composite tool holder; The laser module is activated to preheat the area of ​​the workpiece to be cut; The motion feed module is controlled to feed along a predetermined path to perform composite turning operations; After processing is completed, shut down the laser module, electrolyte delivery system, tool-side ultrasonic vibration system, spindle-side ultrasonic vibration system, and spindle module in sequence, and then return to the motion feed module.

10. The laser preheating-assisted ultrasonic-electrolytic composite turning method according to claim 9, characterized in that, In step 1, the matching relationship between laser power and feed rate is determined with the goal of achieving a surface temperature in the preheating zone that reduces the material's yield strength by 50%. With the dual objectives of minimizing the main cutting force and optimizing the surface quality, the response surface methodology is used to optimize the cutting speed, feed rate, depth of cut, ultrasonic amplitude, and electrolysis voltage. In step 4, the laser spot is located 1mm to 2mm in front of the cutting tool, and the center of the spot is aligned with the cutting edge; The workpiece rotation speed is 300 r / min to 3000 r / min, the ultrasonic vibration frequency is 30 kHz to 40 kHz, and the amplitude is 5 μm to 15 μm; the electrolyte is an aqueous solution of NaNO3; the ultrasonic vibration system on the tool side and the ultrasonic vibration system on the spindle side are synchronously controlled by the bus control system or controlled according to a set phase relationship; the electrolyte is an aqueous solution of NaNO3; the electrolyte delivery system is started 2 to 3 seconds before the laser module is started, so that the electrolyte flows stably before the laser module is turned on; after the laser module is started and stabilized for 1 to 2 seconds, the motion feed module is controlled to start feeding.

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