A device for high-speed interrupted ultrasonic vibration cutting of a part

Abstract

This invention discloses a high-speed intermittent ultrasonic vibration cutting processing device for parts, relating to the field of ultrasonic cutting technology for parts. It includes a complex frequency processing unit housed inside a transducer. The complex frequency processing unit comprises an elastic element, a sphere, and multiple inclined grooves. The elastic element responds to the high-frequency micro-vibration of the transducer, driving the sphere to collide with the inclined grooves at high frequency. The inclined grooves obstruct the sphere, converting the sphere's collision force into an impact force with a lower impact frequency but greater impact force. The complex frequency processing unit also includes an electromagnetic structure comprising multiple sets of electromagnetic components equally spaced and mounted on the outer wall of the amplitude transformer. By adjusting the magnetic force of the electromagnetic components, the impact force of the sphere is compensated to varying degrees. The conversion of vibration mode is achieved through mechanical collision, eliminating the need for complex sets of piezoelectric ceramics and a matching phase synchronization control system. Magnetic compensation can actively intervene in the sphere's motion trajectory and collision energy.

Description

Technical Field

[0001] This invention relates to the field of ultrasonic cutting technology for parts, specifically to a high-speed intermittent ultrasonic vibration cutting device for parts. Background Technology

[0002] Ultrasonic vibration cutting is a machining method that applies ultrasonic frequency vibration to both the cutting tool and the workpiece, causing periodic high-speed separation between them. It transforms the continuous cutting process of constant contact between the tool and workpiece in traditional cutting into high-frequency intermittent cutting, improving the surface quality of the machined parts. Currently, ultrasonic vibration cutting devices include an ultrasonic generator, an ultrasonic transducer, an amplitude transformer, and a cutting tool. The ultrasonic transducer and amplitude transformer are connected by a thread, and the amplitude transformer amplifies the vibration amplitude and transmits it to the tool for ultrasonic vibration cutting. Firstly, at the initial moment of contact with the metal part, the part is in an unsoftened state with high yield strength. The tool needs to apply a great deal of force to overcome the yield strength of the part material before the softening effect of the ultrasound can take effect. This means that the tool needs to consume energy beforehand to penetrate deeply into the part. Secondly, the essence of metal cutting is plastic deformation, and its microscopic nature is the sliding motion of dislocations within the part's crystal under external force. During the cutting penetration process, a large number of dislocations are obstructed and accumulate at grain boundaries, leading to work hardening of the part material and further increasing the cutting force.

[0003] To alleviate this problem, some existing devices synthesize longitudinal and torsional vibrations by outputting multiple sets of piezoelectric ceramics. Specifically, the longitudinal vibration piezoelectric ceramic set generates vibration along the tool axis, while the torsional vibration piezoelectric ceramic set is responsible for generating torsional vibration around the axis. The two sets of vibrations are like two independent structures, which are superimposed and synthesized through a specially designed mechanical structure to finally form a longitudinal-torsional composite vibration on the tool. However, this method requires independent drive signals to drive the piezoelectric ceramics, making the electrical control system complex. Summary of the Invention

[0004] The purpose of this invention is to provide a high-speed intermittent ultrasonic vibration cutting device for parts, so as to solve the problem mentioned in the background art that each piezoelectric ceramic group needs an independent driving signal to drive the piezoelectric ceramic to work, and the electrical control system is complex.

[0005] To achieve the above objectives, the present invention provides the following technical solution: a high-speed intermittent ultrasonic vibration cutting machining device for parts, comprising: a transducer and an amplitude transformer, the amplitude transformer being sleeved on one end of the transducer: The multiple frequency processing unit is located inside the transducer. The multiple frequency processing unit includes an elastic element, a ball and multiple inclined grooves. The elastic element responds to the high-frequency micro-vibration of the transducer and drives the ball to collide with the inclined grooves at a high frequency. The inclined grooves obstruct the ball and convert the collision force of the ball into an impact force with a lower impact frequency but a greater impact force. The multi-frequency processing unit also includes an electromagnetic structure, which includes multiple sets of electromagnetic components installed at equal intervals on the outer wall of the amplitude transformer. The installation positions of the multiple sets of electromagnetic components correspond one-to-one with the opening positions of multiple inclined slots. The impact force of the ball is compensated to different degrees by adjusting the magnetic force of the electromagnetic components. A constraint unit is disposed on one side of the complex frequency processing unit. The constraint unit includes a magnet ring and a magnetic coating. The magnetic coating is magnetically connected to the magnet ring to suppress the radial sway of the elastic element and prevent the torsional shear force in the longitudinal torsional complex frequency impact force from being attenuated due to vibration instability.

[0006] Preferably, the multi-frequency processing unit further includes a base, which is disposed inside the transducer. A first rod is disposed at the bottom of the base, and a second rod is threadedly connected to one end of the first rod.

[0007] Preferably, a limiting washer is provided at one end of the second rod, an elastic element is provided at the bottom of the limiting washer, and a wrapping sleeve is provided at the bottom of the elastic element.

[0008] Preferably, the constraint unit further includes two L-shaped plates, which are symmetrically arranged at the bottom of the limiting washer, and the two sides of the magnet ring are fixedly connected to one side of each of the two L-shaped plates.

[0009] Preferably, the variable amplitude rod body is provided with two U-shaped plates, and each of the two U-shaped plates has a displacement groove on one side.

[0010] Preferably, each of the two displacement grooves is provided with a displacement rod inside, and a positioning plate is sleeved on one end of each of the two displacement rods.

[0011] Preferably, one side of each of the two positioning plates is fixedly connected to one side of each of the two rubber pads, for adjusting the displacement distance of the rubber pads within the amplitude transformer.

[0012] Preferably, the two rubber pads are positioned correspondingly to convert the rigid impact between the sleeve and the amplitude rod into a flexible push.

[0013] Compared with the prior art, the beneficial effects of the present invention are: In this invention, the vibration mode conversion is achieved through mechanical collision, eliminating the need for complex multi-set piezoelectric ceramics and a matching phase synchronization control system. This reduces the cost and electrical control complexity of the device. Magnetic compensation can actively intervene in the trajectory and collision energy of the sphere. When the magnetic attraction force increases, the ball speed increases and the impact force of the ball on the inclined groove is enhanced. When the magnetic attraction force decreases, the ball speed decreases and the impact force of the ball on the inclined groove is weakened. Since the ball speed varies with different magnetic attraction forces, the frequency of the ball's impact on the inclined groove also varies. By adjusting the magnetic force of each electromagnetic component, the magnetic constraint on the ball can be dynamically adjusted during the collision between the ball and the inclined groove, thereby compensating for the impact force of the ball to different degrees and changing the frequency of the ball's impact. Attached Figure Description

[0014] Figure 1 This is a three-dimensional structural diagram of a high-speed intermittent ultrasonic vibration cutting device for parts according to the present invention; Figure 2 This is a partial bottom view of the high-speed intermittent ultrasonic vibration cutting device for parts according to the present invention. Figure 3 This is a partial exploded view of a high-speed intermittent ultrasonic vibration cutting device for parts according to the present invention. Figure 4 This is a schematic diagram of the complex frequency machining unit in a high-speed intermittent ultrasonic vibration cutting device for parts according to the present invention; Figure 5 This is a schematic diagram of the constraint unit in a high-speed intermittent ultrasonic vibration cutting device for parts according to the present invention; Figure 6 This is a partial side cross-sectional view of a high-speed intermittent ultrasonic vibration cutting device for machining parts according to the present invention. Figure 7 This is a schematic cross-sectional view of the internal structure of the amplitude transformer rod in a high-speed intermittent ultrasonic vibration cutting device for parts according to the present invention.

[0015] In the diagram: 100, transducer; 110, amplitude transformer; 200, multi-frequency processing unit; 201, base; 202, first rod; 203, second rod; 204, limiting washer; 205, elastic element; 206, wrapping sleeve; 207, sphere; 208, inclined groove; 210, electromagnetic structure; 300, constraint unit; 301, L-shaped plate; 302, magnet ring; 303, magnetic coating; 304, U-shaped plate; 305, displacement groove; 306, displacement rod; 307, positioning plate; 308, rubber pad. Detailed Implementation

[0016] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0017] This invention provides a high-speed intermittent ultrasonic vibration cutting device for machining parts, with reference to... Figure 1 as well as Figure 2 As shown: It includes a transducer 100 and an amplitude transformer 110. The amplitude transformer 110 is threaded onto one end of the transducer 100. The transducer 100 and the amplitude transformer 110 are rigidly connected by a fine thread. The ultrasonic generator is electrically connected to the transducer 100 via a cable. The other end of the amplitude transformer 110 is also rigidly connected to the cutting tool via a thread, so as to realize ultrasonic vibration cutting of the part material. Existing components require independent drive signals to drive the piezoelectric ceramics, resulting in complex electronic control systems. In contrast, this invention achieves the conversion of vibration modes through mechanical collision.

[0018] like Figure 3 as well as Figure 6As shown, the multi-frequency processing unit 200 is disposed inside the transducer 100, and is integrally disposed in the cavity between the transducer 100 and the amplitude transformer 110. The multi-frequency processing unit 200 includes a spring 205, a ball 207, and multiple inclined grooves 208. The multiple inclined grooves 208 are respectively formed on the inner surface of the amplitude transformer 110. The surface of the inclined grooves 208 is clean and smooth, reducing unnecessary friction and energy loss. The inclined grooves 208 achieve a smooth finish through laser processing and polishing. One end of the spring 205 is fixed, and the other end is a free end that drives the ball 207. Under the elastic drive of the spring 205, the ball 207 periodically collides and contacts the inclined grooves 208 on the inner surface of the amplitude transformer 110. The spring 205 can drive the ball 207 to swing and make circumferential contact with the inclined grooves 208, converting the single high-frequency micro-vibration input from the transducer 100 into a low-frequency but high-impulse longitudinal torsional multi-frequency impact force. This composite impact energy continuously softens the part material and reduces its yield stress. Specifically, during the interval between the two collisions between the ball 207 and the groove 208, the micro-vibration of the transducer 100 continuously does work on the elastic element 205. The elastic element 205 causes the impact force when the ball 207 is released to increase. Therefore, the instantaneous impact force amplitude acting on the groove 208 far exceeds the driving force amplitude of the original micro-vibration of the transducer 100. The larger impact force can inject sufficient strain energy into the material, causing severe distortion of the internal lattice of the material, thereby reducing the external stress required for dislocation slip, which is manifested as a decrease in macroscopic yield stress, creating favorable conditions for subsequent continuous cutting. It is worth noting that due to the presence of the groove 208, the ball 207 will be hindered to a certain extent when it retracts, so that the impact force at the groove 208 is greater than that at the smooth inner surface of the amplitude transformer 110. This structure achieves vibration mode conversion through mechanical collision, eliminating the need for complex multi-group piezoelectric ceramics and matching phase synchronization control system, thus reducing the cost and electrical control complexity of the device, through the collision between the ball 207 and the inclined groove 208.

[0019] like Figure 4As shown, the multi-frequency processing unit 200 also includes an electromagnetic structure 210. The electromagnetic structure 210 includes multiple sets of electromagnetic components equally spaced and installed on the outer wall of the amplitude transformer 110. The installation positions of these electromagnetic components correspond one-to-one with the opening positions of multiple inclined slots 208. The electromagnetic components are electrically connected to an external adjusting resistor and an adjustable power supply. An external control unit controls the power supply level and the resistance of the adjustable resistor, thereby controlling the magnetic force of the electromagnetic structure 210. The magnetic attraction force generated by the electromagnetic structure 210 acts on the sphere 207. A stronger magnetic attraction force provides more precise guidance for the sphere 207, ensuring it impacts the inclined slot 208 strictly along a predetermined trajectory. Increasing the ball speed of the sphere 207 enhances its impact force on the inclined slot 208. Conversely, a weaker magnetic attraction force reduces the ball speed and weakens its impact force on the inclined slot 208. Due to the different magnetic attraction forces, the ball speed of the sphere 207 varies. Therefore, the frequency of the impact of the ball 207 on the inclined groove 208 is also different. By adjusting the magnetic force of each electromagnetic component, the magnetic constraint on the ball 207 during the collision between the ball 207 and the inclined groove 208 can be dynamically adjusted, thereby compensating for the impact force of the ball 207 to different degrees and changing the impact frequency of the ball 207. The multi-frequency processing unit 200 also includes a base 201, which is fixedly welded inside the transducer 100. A first rod 202 is provided at the bottom of the base 201, and the two are welded together. The first rod 202 mainly supports the sleeve 206. A second rod 203 is threadedly connected to one end of the first rod 202. When the second rod 203 is rotated in the opposite direction, the second rod 203 separates from the first rod 202, which facilitates the disassembly and maintenance of the ball 207. The surface of the second rod 203 is coated with anti-loosening adhesive to prevent loosening caused by high-frequency vibration.

[0020] like Figure 4As shown, a limiting washer 204 is provided at one end of the second rod 203, and the two are welded together to support the spring 205, forming a solid whole to ensure that it will not loosen under high-frequency vibration. The preload of the spring 205 is adjusted by rotating the second rod 203, thereby controlling the initial magnitude of the impact force. One end of the spring 205 is connected to the bottom of the limiting washer 204, and the two are welded together. The limiting washer 204 acts as a platform for smooth force transmission, evenly transmitting the pressure of the second rod 203 and the rebound force of the spring 205, preventing the spring 205 from becoming unstable. One end of the spring 205 is used to support the sleeve 206, and the top of the sleeve 206 is connected to the other end of the spring 205, and the two are welded together. The sleeve 206 can reduce the impact between the ball 207 and the amplitude rod 11. The friction loss of the inner wall is zero, and the inner wall of the amplitude rod 110 is protected from direct impact and damage by the ball 207. The spring 205 stores energy when the ball 207 is locked, provides initial impact kinetic energy when released, and maintains the high-frequency reciprocating oscillation of the ball 207. When the transducer 100 is started, the spring 205 will enhance the elastic potential energy of the ball 207, causing the sleeve 206 and the ball 207 inside to start to accelerate oscillation. After the ball 207 collides with the inclined groove 208 on the inner wall of the amplitude rod 110, the spring 205 will absorb the rebound energy and prepare for the next drive. This cycle transforms the high-frequency micro-vibration of the transducer 100 into a powerful impact force, which can generate local stress in a short time, break through the accumulation of dislocations, break through the pile-up group, allow a large number of dislocations to continue to slide, and alleviate work hardening.

[0021] Furthermore, such as Figure 4 As shown, the sphere 207 is made of cemented carbide, and the sheath 206 is made of polytetrafluoroethylene (PTFE). The sheath 206 can reduce the friction between the sphere 207 and the inner wall of the amplitude transformer 110, and concentrate the impact energy to the tool surface for cutting. The sheath 206 tightly wraps around the outside of the sphere 207, and the two are arranged in a concentric nested layout. The sphere 207 is located in the inner center of the sheath 206, and the sheath 206 completely covers the outer surface of the sphere 207. The two are tightly fitted, and they will not slide or rotate relative to each other under high-frequency impact. The impact kinetic energy is mainly provided by cemented carbide, and the buffer, friction reduction and guidance are achieved by PTFE.

[0022] like Figure 5As shown, the constraint unit 300 is disposed on one side of the complex frequency processing unit 200. The constraint unit 300 includes a magnet ring 302 and a magnetic coating 303. The magnetic coating 303 is coated on one end surface of the spring 205. The magnetic coating 303 and the magnet ring 302 are attracted to each other by magnetic attraction and are magnetically connected. When the spring 205 swings laterally, the magnetic attraction between the magnetic coating 303 and the magnet ring 302 generates a centripetal force, pulling the spring 205 back to the center position. This not only constrains the lateral swing amplitude of the spring 205 but also prevents mechanical friction loss, limiting the free lateral swing of the spring 205 to a safe range. The constraint unit 300 also includes two rubber pads 308 located around the spring 205. When the lateral swing amplitude of the spring 205 exceeds a preset value, the spring 205 will interact with the rubber pads 308. Upon contact, the rubber pad 308 absorbs the impact kinetic energy through its own elastic deformation, converting it into heat and dissipating it. After contact, the rubber pad 308 generates a reaction force that pushes the spring 205 back to the center, further suppressing its lateral sway. When the spring 205 oscillates normally with a small amplitude, the magnetic force takes effect; when it oscillates abnormally with a large amplitude, the rubber pad 308 intervenes as a mechanical stop and buffer. The rubber pad 308 can soften the impact and stabilize the movement of the spring 205. The constraint unit 300 also includes two L-shaped plates 301, which are respectively set at the bottom of the limiting washer 204. The L-shaped plates 301 and the bottom of the limiting washer 204 are fixed by welding. The magnet ring 302 is connected to one side of each of the two L-shaped plates 301, and the two are welded together. The L-shaped plates 301 provide structural support for the entire constraint unit 300, fixing the magnet ring 302 in a precise position and ensuring that the direction of the magnetic force is correct.

[0023] It is worth noting that the magnetic coating 303 uses vacuum ion plating to enhance adhesion.

[0024] like Figure 7 as well as Figure 3As shown, two U-shaped plates 304 are installed inside the luffing rod 110, welded together and symmetrically arranged inside the luffing rod 110. Each U-shaped plate 304 has a displacement groove 305 on one side, which is a guide groove. A displacement rod 306 is installed inside each displacement groove 305, sliding axially within the groove. A positioning plate 307 is fitted onto one end of each displacement rod 306, and the two are fixedly fitted together. The positioning plate 307 is made of wear-resistant copper alloy, providing wear resistance and cushioning. The positioning plate 307 connects... The displacement rod 306 and the rubber pad 308 increase the installation contact area of ​​the rubber pad 308, preventing the rubber pad 308 from curling or shifting during compression. The movement of the displacement rod 306 drives the positioning plate 307 to move the rubber pad 308. One side of each of the two positioning plates 307 is connected to one side of each of the two rubber pads 308, and the two are welded together. This is used to adjust the displacement distance of the rubber pad 308 within the amplitude transformer 110. The two rubber pads 308 are positioned correspondingly, which can convert the rigid impact between the sleeve 206 and the amplitude transformer 110 into a flexible impact. The magnetic force between the magnetic coatings 303 and 303 constrains the spring 205 to the center position. The spring 205 instantaneously releases its stored elastic potential energy, driving the wrapping sleeve 206 and the internal ball 207 to oscillate axially with acceleration. Driven by the spring 205, the ball 207 gains initial kinetic energy and begins its first collision with the inclined groove 208 on the inner wall of the amplitude transformer 110. During the reciprocating extension and retraction of the spring 205, its lateral oscillation is continuously constrained by the constant magnetic force between the magnet ring 302 and the magnetic coating 303. When the wrapping sleeve 206 oscillates slightly: The sheath 206 maintains a gap with the rubber pads 308 on both sides, without contact or additional resistance. When the sheath 206 swings significantly due to resonance, it will contact and squeeze one of the rubber pads 308. The rubber pad 308 will undergo elastic compression deformation, absorbing the impact kinetic energy. At the same time, it will push the displacement rod 306 to slide outward along the displacement groove 305, converting the rigid impact into a flexible push. The impact force is reduced. After the abnormal impact, the sheath 206 swings back, the rubber pad 308 elastically recovers, and pushes the displacement rod 306 back to its initial position, automatically restoring to the normal gap state.

[0025] Although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art can still modify the technical solutions described in the foregoing embodiments or make equivalent substitutions for some of the technical features. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the protection scope of the present invention.

Claims

1. A high-speed intermittent ultrasonic vibration machining device for parts, comprising: A transducer (100) and an amplitude transformer (110), the amplitude transformer (110) being sleeved on one end of the transducer (100), characterized in that: A multi-frequency processing unit (200) is disposed inside the transducer (100). The multi-frequency processing unit (200) includes an elastic element (205), a sphere (207), and multiple inclined grooves (208). The elastic element (205) responds to the high-frequency micro-vibration of the transducer (100) and drives the sphere (207) to collide with the inclined grooves (208) at high frequency. The inclined grooves (208) obstruct the sphere (207) and convert the collision force of the sphere (207) into an impact force with a lower impact frequency but a greater impact force. The multi-frequency processing unit (200) also includes an electromagnetic structure (210), which includes multiple sets of electromagnetic components installed at equal intervals on the outer wall of the amplitude rod (110). The installation positions of the multiple sets of electromagnetic components correspond one-to-one with the opening positions of multiple inclined slots (208). The impact force of the ball (207) is compensated to different degrees by adjusting the magnetic force of the electromagnetic components. A constraint unit (300) is disposed on one side of the multi-frequency processing unit (200). The constraint unit (300) includes a magnet ring (302) and a magnetic coating (303). The magnetic coating (303) is magnetically connected to the magnet ring (302) to suppress the radial sway of the elastic element (205) and prevent the torsional shear force in the longitudinal torsional multi-frequency impact force from being attenuated due to vibration instability.

2. The high-speed intermittent ultrasonic vibration cutting device for parts according to claim 1, characterized in that: The multi-frequency processing unit (200) also includes a base (201), which is located inside the transducer (100). A first rod (202) is provided at the bottom of the base (201), and a second rod (203) is threaded to one end of the first rod (202).

3. The high-speed intermittent ultrasonic vibration cutting device for parts according to claim 2, characterized in that: One end of the second rod (203) is provided with a limiting washer (204), an elastic element (205) is provided at the bottom of the limiting washer (204), and a sleeve (206) is provided at the bottom of the elastic element (205).

4. The high-speed intermittent ultrasonic vibration cutting device for parts according to claim 3, characterized in that: The constraint unit (300) also includes two L-shaped plates (301), which are symmetrically arranged at the bottom of the limiting washer (204). The magnet ring (302) is fixedly connected to one side of each of the two L-shaped plates (301).

5. The high-speed intermittent ultrasonic vibration cutting device for parts according to claim 1, characterized in that: The variable amplitude rod (110) is provided with two U-shaped plates (304), and a displacement groove (305) is provided on one side of each of the two U-shaped plates (304).

6. The high-speed intermittent ultrasonic vibration cutting device for parts according to claim 5, characterized in that: The interior of each of the two displacement grooves (305) is provided with a displacement rod (306), and a positioning plate (307) is sleeved on one end of each of the two displacement rods (306).

7. The high-speed intermittent ultrasonic vibration cutting device for parts according to claim 6, characterized in that: One side of each of the two positioning plates (307) is fixedly connected to one side of each of the two rubber pads (308) to adjust the displacement distance of the rubber pads (308) within the amplitude rod (110).

8. The high-speed intermittent ultrasonic vibration cutting device for parts according to claim 7, characterized in that: The two rubber pads (308) are positioned correspondingly to convert the rigid impact of the sleeve (206) and the amplitude rod (110) into a flexible push.

Images