Method for manufacturing a heating net, ultrasonic stamping device and heating net

Abstract

The application relates to a heating net manufacturing method, an ultrasonic stamping device and a heating net. The heating net manufacturing method comprises the following steps: determining an ultrasonic amplitude applied to a punch body of the ultrasonic stamping device according to a target aperture of a mesh hole of the heating net; determining an ultrasonic frequency of the ultrasonic stamping device according to a hole spacing between two adjacent mesh holes in the heating net; driving the punch body to perform a punching operation on a to-be-processed plate to form the mesh hole of the heating net on the to-be-processed plate; and wherein the punching operation adopts an alternating punching mode, the alternating punching mode comprises that the punch body alternately performs ultrasonic punching for a first set number of times and non-ultrasonic punching for a second set number of times; and when the ultrasonic punching is performed, the punch body performs ultrasonic vibration according to the ultrasonic frequency and the ultrasonic amplitude. The application is beneficial to prolonging the service life of the punch body, reducing the warping deformation of the plate and improving the through-hole precision.

Description

Technical Field

[0001] This application relates to a method for manufacturing a heating mesh, an ultrasonic stamping device, and a heating mesh. Background Technology

[0002] The electronic heating device uses a metal heating mesh as the heating element, with an array of holes. The mesh is primarily manufactured using processes such as chemical etching, laser drilling, and mechanical stamping. Mechanical stamping involves a punch and die working together to continuously shear and punch holes in a thin metal sheet to form the mesh array. During continuous stamping, the punch is prone to wear, and the sheet metal is susceptible to burrs, hole shape deviations, and residual stress accumulation under shearing action. This can lead to sheet warping and affect subsequent welding and assembly. Summary of the Invention

[0003] The purpose of this application is to provide a method for manufacturing a heating mesh, an ultrasonic stamping device, and a heating mesh, in order to solve the technical problems of punch wear, plate warping and deformation, and decreased accuracy of through holes in the continuous stamping process of heating mesh in related technologies.

[0004] To achieve the above objectives, the technical solution adopted in this application is as follows: This application provides a method for manufacturing a heating mesh, including: The ultrasonic amplitude applied to the punch body of the ultrasonic punching device is determined based on the target aperture of the heating mesh. The ultrasonic frequency of the ultrasonic stamping device is determined based on the spacing between two adjacent mesh openings in the heating mesh. The punch body is driven to punch holes in the sheet metal to be processed, so as to form the mesh of the heating mesh on the sheet metal to be processed; The punching operation adopts an alternating punching mode, which includes: the punch body alternately performing a first set number of ultrasonic punchings and a second set number of non-ultrasonic punchings; during the ultrasonic punching, the punch body performs ultrasonic vibration according to the ultrasonic frequency and the ultrasonic amplitude.

[0005] In some implementations, determining the ultrasonic amplitude applied to the punch body of the ultrasonic punching device based on the target aperture of the heating mesh includes: When the target aperture d is less than 0.05 mm, the ultrasonic amplitude A is determined to be greater than 10 μm and less than or equal to 15 μm; When the target aperture d is not less than 0.05 mm, the ultrasonic amplitude A is determined to be greater than or equal to 5 μm and less than or equal to 10 μm.

[0006] In some implementations, the hole spacing p and the ultrasonic frequency f satisfy the following relationship: f=k / (n×p), where n is a positive integer and 20kHz≤f≤40kHz, and k is a propagation speed parameter corresponding to the material of the plate to be processed.

[0007] In some implementations, when the material of the plate to be processed is stainless steel, the propagation velocity parameter k is 800m / s to 1100m / s; When the material of the plate to be processed is a nickel-chromium alloy, the propagation velocity parameter k is 700m / s~1000m / s; When the material of the plate to be processed is titanium alloy, the propagation speed parameter k is 900m / s~1300m / s.

[0008] In some implementations, after determining the ultrasonic amplitude applied to the punch body of the ultrasonic punching device and before driving the punch body to perform a punching operation on the sheet metal to be processed, the heating mesh manufacturing method further includes: The radius of the fillet of the cutting edge of the punch body is determined based on the ultrasonic amplitude.

[0009] In some implementations, the fillet radius r and the ultrasonic amplitude A satisfy the relationship: r = αA, where α is the fillet coefficient and 0.3 ≤ α ≤ 0.6.

[0010] In some implementations, the first set number of times N and the second set number of times M satisfy the relationship: N / M≥ 15.

[0011] In some implementations, the first set number of times N is 50 to 200 times, and the second set number of times M is 3 to 10 times.

[0012] This application provides an ultrasonic stamping device, comprising: stamping frame; A punch assembly is mounted on the stamping frame. The punch assembly includes a punch body and an ultrasonic transducer acoustically coupled to the punch body. The punch body has an annular waveguide groove on its stamping end face. A controller, electrically connected to the ultrasonic transducer, is used to determine the ultrasonic amplitude based on the target aperture of the heating mesh, determine the ultrasonic frequency based on the spacing between two adjacent mesh openings in the heating mesh, and output a control signal to the ultrasonic transducer to drive the punch body to perform ultrasonic punching on the material to be processed in an alternating punching mode. The alternating punching mode includes the punch body alternately performing a first set number of ultrasonic punchings and a second set number of non-ultrasonic punchings.

[0013] In some implementations, there are multiple annular waveguide slots, and the multiple annular waveguide slots are arranged concentrically; The spacing between two adjacent annular waveguide slots is 0.1mm to 0.3mm, the depth of the annular waveguide slot is 0.1mm to 0.5mm, and the width of the annular waveguide slot is 0.05mm to 0.2mm.

[0014] In some implementations, the cutting edge of the punch body is provided with a rounded corner radius corresponding to the ultrasonic amplitude; The fillet radius r of the cutting edge and the ultrasonic amplitude A satisfy the following relationship: r = αA, where α is the fillet coefficient and 0.3 ≤ α ≤ 0.6.

[0015] This application provides a heating mesh, which is manufactured using the heating mesh manufacturing method described in any of the above implementations; Alternatively, it can be manufactured using the ultrasonic stamping device described in any of the above implementation methods.

[0016] The beneficial effects of the heating mesh manufacturing method, ultrasonic stamping device, and heating mesh provided in this application are mainly as follows: The punch body of this application employs an alternating punching mode during the punching operation. After performing a first set number of ultrasonic punching cycles, a second set number of non-ultrasonic punching cycles are performed consecutively. This helps alleviate thermal wear of the punch body and thermal deformation of the workpiece caused by the continuous accumulation of ultrasonic energy. The high-frequency vibration of ultrasonic energy during ultrasonic punching reduces the punching shear force, which helps suppress the accumulation of residual stress inside the workpiece, reducing the possibility of warping deformation and thus improving the yield of subsequent welding and assembly processes. The non-ultrasonic punching stage provides a buffer for heat dissipation and stress release for the punch body, helping to maintain the shape accuracy of the through holes in the heating mesh and reducing the possibility of hole shape deviation and burr formation. Furthermore, this optimized intermittent ultrasonic punching design also helps delay the wear of the punch body's cutting edge, contributing to a longer service life of the ultrasonic punching device. Attached Figure Description

[0017] To more clearly illustrate the technical solutions in the embodiments of this application, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of this application. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0018] Figure 1 This is a schematic diagram illustrating the corner collapse that occurs in sheet metal during the mechanical stamping process of related technologies; Figure 2 This is a schematic diagram showing burrs on the edge of holes during the mechanical stamping process of related technologies; Figure 3 This is a schematic diagram illustrating the warping of sheet metal during the mechanical stamping process of related technologies; Figure 4 This is a schematic flowchart of the heating mesh manufacturing method provided in the embodiments of this application; Figure 5 These are curves showing the test results of ultrasonic amplitude matching and processing performance under different target apertures provided in the embodiments of this application; Figure 6 This is a graph showing the comparison of the temperature of the sheet metal to be processed when the punching operation is performed in continuous mode and intermittent mode, as provided in the embodiments of this application. Figure 7 This is a graph showing the wear amount of the cutting edge of the punch body provided in this application embodiment and the wear amount of the cutting edge of the punch body in related technologies. Figure 8 This is a bar chart comparing the performance of ultrasonic-assisted stamping and mechanical stamping, as provided in the embodiments of this application. Figure 9 This is a schematic diagram of the ultrasonic stamping device provided in the embodiments of this application; Figure 10 This is a schematic diagram of the structure of the punch body provided in the embodiments of this application; Figure 11 It is along Figure 10 Sectional view of line AA in the middle; Figure 12 This is a schematic diagram of the structure of the heating mesh provided in the embodiment of this application.

[0019] Explanation of key figure labels: 1. Sheet metal; 2. Punch; 3. Burr; 4. Collapsed corner; 10. Ultrasonic stamping device; 11. Stamping frame; 111. Frame body; 112. Crossbeam; 12. Punch assembly; 121. Punch body; 1211. Cutting edge; 1212. Rounded corner; 1213. Stamping end face; 1214. Annular waveguide groove; 1215. Cooling channel; 122. Ultrasonic transducer; 1221. Piezoelectric ceramic stack; 123. Amplifier rod; 13. Controller; 14. Force sensor; 15. Die; 16. Worktable; 20. Plate to be processed; 30. Heating grid; 31. Mesh. Detailed Implementation

[0020] In related technologies, the heating element in an electronic atomizing device uses a metal heating mesh as the heating component, and the heating mesh has a mesh array. The mesh openings of the heating mesh are mainly manufactured using processes such as chemical etching, laser drilling, and mechanical stamping. Specifically, chemical etching involves forming a mask with photoresist and then using an etching solution to etch a thin metal plate to create through-holes; laser drilling uses a pulsed laser to ablate the material hole by hole to create the mesh. See also... Figures 1 to 3As shown, mechanical stamping utilizes the cooperation of punch 2 and die to shear and punch holes in thin metal sheets to form a hole array. During the mechanical stamping process, punch 2 repeatedly enters the sheet 1 and completes shearing. When the size of punch 2 decreases to the range of mesh processing, punch 2 is prone to wear or breakage under continuous pressure and repeated impact. After the sheet 1 is sheared and squeezed, the hole opening and hole wall undergo elastoplastic deformation, and the hole edge is prone to forming a collapsed corner 4, tilting and burrs 3. The height v1 of the hole edge burrs 3 can reach 8μm ~ 15μm. With continuous stamping of the mesh array, the residual stress inside the sheet 1 gradually accumulates. The punch 2 and the sheet 1 are in continuous contact and friction, accompanied by plastic deformation of the material. Heat gradually accumulates in the local area, and the sheet 1 as a whole warps. The warping amount w1 of the sheet 1 can reach 0.10mm ~ 0.20mm, which in turn affects the subsequent welding and assembly process.

[0021] Therefore, this application provides a method for manufacturing a heating mesh, an ultrasonic stamping device, and a heating mesh to solve the problems in the related art where punch wear, continuous accumulation of plate stress, and local heat accumulation during the continuous stamping process of the heating mesh lead to plate warping and deformation, and a decrease in the size and shape accuracy of through holes.

[0022] To make the technical problems, technical solutions, and beneficial effects to be solved by this application clearer, the following detailed description is provided in conjunction with the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are merely illustrative and are not intended to limit the scope of this application.

[0023] Combination Figure 4 and Figure 9 As shown, the heating mesh manufacturing method provided in this application embodiment may include at least some or all of the following steps. This heating mesh manufacturing method may be performed by the ultrasonic stamping device 10.

[0024] Step S100: Determine the ultrasonic amplitude applied to the punch body 121 of the ultrasonic punching device 10 based on the target aperture of the mesh 31 of the heating mesh 30.

[0025] For example, before processing begins, the processing parameters of the heating mesh 30 are obtained, including the target aperture information. The heating mesh 30 can have multiple mesh openings 31, which can be arranged in an array, either in rows and columns or other regular patterns. The shape of the mesh openings 31 can be circular, elliptical, or polygonal. When the mesh openings 31 are non-circular, the target aperture can be the maximum radial distance of the mesh openings 31.

[0026] Step S200: Determine the ultrasonic frequency of the ultrasonic stamping device 10 based on the hole spacing between two adjacent mesh holes 31 in the heating mesh 30.

[0027] For example, the processing parameters also include the hole spacing between two adjacent mesh holes 31 in the heating mesh 30. When there are multiple regions with different hole spacings in the heating mesh 30, the ultrasonic frequency can also be adjusted according to different processing regions to adapt to the punching processing requirements of the corresponding regions.

[0028] Step S300: Drive the punch body 121 to perform a punching operation on the plate 20 to be processed, so as to form the mesh 31 of the heating mesh 30 on the plate 20 to be processed; wherein, the punching operation adopts an alternating punching mode, which includes: the punch body 121 alternately performs a first set number of ultrasonic punchings and a second set number of non-ultrasonic punchings; during ultrasonic punching, the punch body 121 performs ultrasonic vibration according to the ultrasonic frequency and ultrasonic amplitude.

[0029] For example, during the processing of the ultrasonic stamping device 10, the punch body 121 can be controlled to move relative to the plate 20 to be processed according to the set processing path, so that the punch body 121 sequentially completes the stamping processing of each mesh 31. The punch body 121 can be driven by a servo motor in conjunction with a lead screw mechanism, linear module, electric cylinder, pneumatic cylinder or hydraulic drive mechanism to perform reciprocating motion, and the embodiments of this application do not limit this.

[0030] After the punch body 121 performs a first set number of ultrasonic punching operations, the ultrasonic vibration output to the punch body 121 is paused, allowing the punch body 121 to perform a second set number of non-ultrasonic punching operations. Then, ultrasonic vibration is resumed, and the above processing process is repeated until all mesh holes 31 are processed. The first and second set number of operations can be set according to the material of the sheet 20 to be processed, the sheet thickness, the mesh hole size 31, the punching density, or the processing requirements. Alternatively, they can be automatically determined by the control program calling preset process parameters; this embodiment does not limit this. During the non-ultrasonic punching stage, the punch body 121 still completes the punching according to the set punching trajectory, only the ultrasonic vibration output is stopped.

[0031] Understandably, in punching operations, the order of ultrasonic punching and non-ultrasonic punching is not important; that is, ultrasonic punching can be performed first, followed by non-ultrasonic punching, or vice versa. Furthermore, a preset time interval can be set between ultrasonic and non-ultrasonic punching to allow heat dissipation from the punch body and / or the workpiece, thereby reducing temperature rise during processing, improving punching stability, and extending the punch's lifespan.

[0032] Through the above settings, the punch body 121 adopts an alternating punching mode during the punching operation. After performing a first set number of ultrasonic punching operations, a second set number of non-ultrasonic punching operations are performed. This helps to alleviate the thermal wear of the punch body 121 and the thermal deformation of the sheet material 20 caused by the continuous accumulation of ultrasonic energy. The high-frequency vibration of ultrasonic energy during ultrasonic punching can reduce the punching shear force, which helps to suppress the accumulation of residual stress inside the sheet material 20 and reduce the possibility of warping deformation, thereby helping to improve the yield of subsequent welding and assembly processes. The non-ultrasonic punching stage can provide a buffer for heat dissipation and stress release for the punch body 121, which helps to maintain the shape accuracy of the through holes of the heating mesh 30 and can reduce the possibility of hole shape deviation and burr formation. In addition, this optimized design of intermittent ultrasonic punching also helps to delay the wear of the cutting edge 1211 of the punch body 121, which helps to extend the service life of the ultrasonic punching device 10.

[0033] In some embodiments, for step S100, the method of determining the ultrasonic amplitude applied to the punch body 121 of the ultrasonic punching device 10 according to the target aperture of the mesh 31 of the heating mesh 30 includes: when the target aperture d is less than 0.05 mm, determining the ultrasonic amplitude A to be greater than 10 μm and less than or equal to 15 μm; when the target aperture d is not less than 0.05 mm, determining the ultrasonic amplitude A to be greater than or equal to 5 μm and less than or equal to 10 μm. This method of matching the ultrasonic amplitude to the target aperture size is beneficial for precise control of energy input during micro-hole processing. Using a larger ultrasonic amplitude when the target aperture is less than the micro-hole critical value helps reduce frictional resistance during micro-hole punching through high-frequency strong vibration, reducing the risk of punch breakage and minimizing micro-hole burrs; using a smaller ultrasonic amplitude when the target aperture is not less than the critical value helps prevent springback deformation of the sheet metal caused by excessive vibration, helps maintain the morphological accuracy of large-diameter through holes, and facilitates the synergistic improvement of processing efficiency and forming quality under different aperture sizes.

[0034] For example, a method for determining the ultrasonic amplitude applied to the punch body 121 of the ultrasonic punching device 10 based on the target aperture of the mesh 31 of the heating mesh 30 includes: obtaining the target aperture of the mesh 31 of the heating mesh 30, and comparing the target aperture with a preset aperture range to determine the corresponding ultrasonic amplitude range. The specific value of the ultrasonic amplitude can be set according to the material type, thickness, and processing requirements of the sheet material 20 to be processed, or it can be determined according to a preset process parameter library. This embodiment does not limit this. A smaller target aperture corresponds to a larger ultrasonic amplitude; a larger target aperture corresponds to a smaller ultrasonic amplitude, to meet the punching processing requirements of different apertures.

[0035] Table 1:

[0036] Table 1 shows the test results of ultrasonic amplitude matching and processing performance under different target apertures. Based on Table 1 and... Figure 5 It can be seen that when the target hole diameter d is less than 0.05 mm, using an ultrasonic amplitude of 10 μm or more for punching can effectively reduce the punching force during the micro-hole punching process and reduce burr height and roundness deviation. When the target hole diameter d is not less than 0.05 mm, using an ultrasonic amplitude of 5 μm to 10 μm for punching can maintain a low punching force while helping to maintain the shape accuracy of the mesh 31. Compared with Comparative Examples 1 and 2, where the amplitude and target hole diameter are mismatched, this application determines the ultrasonic amplitude according to the target hole diameter, which can keep the processing performance such as punching force, burr height, and roundness deviation at a better level. This shows that matching the corresponding ultrasonic amplitude for different target hole diameters is beneficial to balancing processing efficiency and hole shape quality. Compared to Example 5, Comparative Example 1 has an amplitude lower than the specified lower limit of 10μm to 15μm, and its roundness deviation (6.5%) is significantly higher than that of Example 5 (1.8%), which cannot guarantee high-precision forming. Compared to Example 6, Comparative Example 2 has a reduced punching force, but because its amplitude exceeds the specified upper limit of 5μm to 10μm, its roundness deviation (4.8%) is significantly higher than that of Example 6 (2.1%), which cannot guarantee high-precision forming. This proves the necessity of the graded design in this application.

[0037] In some embodiments, in step S100, i.e., after determining the ultrasonic amplitude applied to the punch body 121 of the ultrasonic punching device 10, and before driving the punch body 121 to perform a punching operation on the sheet metal 20 to be processed, the heating mesh manufacturing method further includes: Step S110: Based on the ultrasonic amplitude, determine the radius of the rounded corner 1212 of the cutting edge 1211 of the punch body 121. This helps optimize the stress distribution between the punch body 121 and the plate contact surface under high-frequency vibration. By designing the rounded corner 1212 to match a specific amplitude, local stress concentration can be effectively avoided, reducing the risk of abnormal damage such as chipping or breakage of the punch cutting edge 1211 under continuous high-frequency impact. Simultaneously, a reasonable rounded corner transition also helps improve the hole quality of the heating mesh 30 and reduce burrs on the edges of the mesh holes 31 of the heating mesh 30.

[0038] For example, the cutting edge 1211 of the punch body 121 is located at the end of the punch body 121 that contacts the sheet metal 20 to be processed. The cutting edge 1211 of the punch body 121 has a rounded corner 1212; according to the determined radius of the rounded corner 1212, the cutting edge 1211 of the punch body 121 is rounded to form an arc transition structure with a corresponding radius, that is, a rounded corner 1212 is formed. The rounded corner 1212 can be formed by grinding, electrical discharge machining, laser finishing, precision polishing or other mold processing methods, and this application embodiment does not limit this. The punch body 121 with the corresponding rounded corner 1212 can be installed on the ultrasonic punching device 10 for subsequent ultrasonic punching processing.

[0039] It should be noted that step S200 can also be placed before steps S100 and S110.

[0040] In some embodiments, the radius r of the fillet 1212 and the ultrasonic amplitude A satisfy the relationship: r=αA, where α is the fillet coefficient and 0.3≤α≤0.6. This ensures that the radius of the fillet 1212 can effectively disperse the shear stress caused by high-frequency vibration and reduce the risk of chipping of the cutting edge 1211, while avoiding severe corner collapse or burrs caused by excessive fillet radius. This helps to achieve a balance between protecting the mold and maintaining the hole shape accuracy of the heating mesh 30, and helps to maintain the stability of continuous processing.

[0041] For example, the fillet factor α can be set according to the punch material, the material type of the plate 20 to be processed, the plate thickness and the processing requirements. The fillet factor α can be 0.3, 0.4, 0.5 or 0.6, and this embodiment does not limit it.

[0042] In some embodiments, in step S200, the hole spacing p and the ultrasonic frequency f satisfy the following relationship: f=k / (n×p), where n is a positive integer and 20kHz≤f≤40kHz, and k is the propagation speed parameter corresponding to the material of the plate 20 to be processed. This helps to maintain the overall flatness of the plate, which not only helps to improve the bonding accuracy of subsequent automated welding, but also helps to improve the uniformity of hole arrangement when multiple rows of punches are working at the same time.

[0043] For example, when the calculated ultrasonic frequency exceeds the operating frequency range of the ultrasonic stamping device 10, the calculated frequency is down-clocked by adjusting the positive integer n, so that the adjusted ultrasonic frequency is within the range of 20 kHz to 40 kHz. The positive integer n is used to adjust the correspondence between the ultrasonic wave length and the hole spacing of the heating mesh 30. n can represent the number of hole spacings covered by one ultrasonic wavelength. Its value can make the ultrasonic wave length and hole spacing meet a preset ratio relationship, so as to reduce the influence of stress wave interference between adjacent mesh holes 31 on the stress distribution. This application embodiment does not limit this.

[0044] In some embodiments, when the material of the sheet metal 20 to be processed is stainless steel, the propagation velocity parameter k is 800 m / s to 1100 m / s, for example, k can be 800 m / s, 900 m / s, 1000 m / s, or 1100 m / s. When the material of the sheet metal 20 to be processed is nickel-chromium alloy, the propagation velocity parameter k is 700 m / s to 1000 m / s, for example, k can be 700 m / s, 800 m / s, 900 m / s, or 1000 m / s. When the material of the sheet metal 20 to be processed is titanium alloy, the propagation velocity parameter k is 900 m / s to 1300 m / s, for example, k can be 900 m / s, 1000 m / s, 1100 m / s, 1200 m / s, or 1300 m / s. In this way, the corresponding propagation speed parameter k is selected according to the material type of the plate 20 to be processed, and the ultrasonic frequency is determined in combination with the hole spacing of the heating mesh 30. This ensures that the ultrasonic wave length corresponds to the hole spacing of the heating mesh 30, reduces the influence of stress wave interference between adjacent mesh holes 31 on stress distribution, and also helps to maintain the hole shape quality of the heating mesh 30 of each material.

[0045] Table 2:

[0046] Table 2 shows the theoretical calculation results of the ultrasonic frequency f for different materials under different aperture spacing p. In the theoretical calculation, n=1, meaning the theoretical frequency is calculated according to the formula f=k / p, to determine the corresponding relationship between ultrasonic frequencies for different materials and different aperture spacings. As shown in Table 2, with a constant propagation velocity parameter k, the theoretically calculated ultrasonic frequency f gradually decreases as the aperture spacing p increases. Under the same aperture spacing, different materials exhibit different theoretical ultrasonic frequencies due to variations in the propagation velocity parameter k. Ti-6Al-4V titanium alloy has the highest theoretical ultrasonic frequency, followed by SS316L stainless steel, while Ni80 nickel-chromium alloy has the lowest.

[0047] It is understandable that the theoretical frequencies calculated based on n=1 in Table 2 are mostly in the megahertz (MHz) range. In actual industrial ultrasonic stamping, due to the limitations of the physical rated operating range of the ultrasonic transducer (usually 20kHz~40kHz), these theoretical frequencies cannot be directly used for processing. In the actual processing, an appropriate positive integer n can be selected based on the above theoretical frequencies, and the actual operating frequency can be determined according to the relationship f=k / (n×p) to control the ultrasonic operating frequency within the operating range of 20kHz~40kHz. This ensures that the ultrasonic wave length and the hole spacing of the heating mesh 30 maintain a preset correspondence, which helps to reduce the influence of stress wave interference between adjacent mesh holes 31 on the stress distribution, and improves the punching quality and processing stability.

[0048] Before actual processing, the theoretical value is calculated according to the formula n = k / (f0×p) (where f0 is the rated center frequency of the ultrasonic transducer 122, such as 30kHz). Then, the calculated theoretical value is rounded up, down, or to the nearest integer to obtain a positive integer n. Finally, n is substituted back into the original formula to correct and obtain the ultrasonic frequency f during actual operation.

[0049] It is understood that the material 20 to be processed is not limited to stainless steel, nickel-chromium alloy and titanium alloy, but can also be iron-chromium-aluminum alloy (FeCrAl), pure nickel, nickel-iron alloy, copper-based resistive material or other conductive metal or alloy material suitable for resistive heating elements. This application does not limit it in this regard.

[0050] In some embodiments, the first set number of times N is 50 to 200 times, the second set number of times M is 3 to 10 times, and the first set number of times N and the second set number of times M satisfy the relationship: N / M ≥ 15. By matching the first set number of times N and the second set number of times M, the ultrasonic punching process and the non-ultrasonic punching process can be alternated, which, while taking into account the punching efficiency, provides intermittent heat dissipation and stress release time for the punch body 121 to maintain the stability of the continuous punching process.

[0051] For example, the first set number of times N can be 50 times, 80 times, 100 times, 120 times, 150 times or 200 times; the second set number of times M can be 3 times, 5 times, 6 times, 7 times, 8 times or 10 times, and this application embodiment does not limit this.

[0052] Table 3:

[0053] Table 3 compares the temperature of the sheet metal 20 to be processed when the punching operation is performed in continuous mode and intermittent mode in the embodiments of this application. In continuous mode, the ultrasonic punching device 10 continuously outputs ultrasonic vibration throughout the punching process, using ultrasonic punching for all holes without a non-ultrasonic punching phase. In intermittent mode, the punch body 121 performs ultrasonic punching for a first set number of times N, followed by non-ultrasonic punching for a second set number of times M, and repeats this cycle. In Table 3 of the embodiments of this application, the first set number N is 100 times, the second set number M is 5 times, therefore N / M = 20, and each cycle consists of 105 punches.

[0054] From Table 3 and Figure 6 It can be seen that as the number of punching cycles increases, the temperature of the sheet metal 20 under continuous mode continues to rise, reaching 94.9°C after 2000 punching cycles. However, when using the intermittent mode provided in this embodiment, the temperature of the sheet metal 20 remains at a lower level, reaching 40.2°C after 2000 punching cycles. This indicates that the intermittent ultrasonic punching method provided in this embodiment can effectively suppress heat accumulation during the punching process, reduce the temperature rise of the sheet metal 20, help reduce thermal deformation of the sheet metal, maintain hole shape accuracy, and reduce wear on the punch body 121 caused by continuous heating, thereby improving the stability of continuous punching processing.

[0055] Table 4:

[0056] Table 4 compares the wear amount of the cutting edge 1211 of the punch body 121 in this application with the wear amount of the cutting edge 1211 of the punch body 121 in related technologies. (From Table 4 and...) Figure 7 It is known that, under the condition that the wear of the cutting edge 1211 of the punch body 121 reaches 10μm as the failure criterion, the punch body 121 in the mechanical stamping process of the related technology reaches the failure condition after a cumulative stamping of 75,000 times; when using the ultrasonic-assisted stamping process in the embodiment of this application, the punch body 121 reaches the failure condition after a cumulative stamping of 265,000 times, and the service life of the punch body 121 is increased by 3.5 times. Therefore, the heating mesh manufacturing method provided in the embodiment of this application can effectively reduce the wear of the punch body 121 and extend its service life.

[0057] Combination Figure 10 and Figure 11As shown, in some embodiments, multiple annular waveguide grooves 1214 are formed on the stamping end face 1213 of the punch body 121 to process the workpiece 20. The stamping end face 1213 is used to contact the workpiece 20, and the multiple annular waveguide grooves 1214 are concentrically arranged. The multiple concentrically arranged annular waveguide grooves 1214 can guide the propagation of ultrasonic vibrations, concentrating ultrasonic energy more in the area near the cutting edge 1211 of the stamping end face 1213, improving the utilization rate of ultrasonic energy and reducing the diffusion of ultrasonic energy to surrounding areas. This reduces excessive temperature rise in local areas of the workpiece 20 due to uneven energy distribution, reduces local thermal deformation and burr generation, and improves the shearing quality of the edges of the heating mesh 30 holes. Simultaneously, the multiple annular waveguide grooves 1214 also help improve the stress state of the stamping end face 1213, reduce wear on the punch end face, and increase the service life of the punch.

[0058] For example, the number of annular waveguide grooves 1214 on the stamping end face 1213 can be 2, 3, 4, 5 or more. When ultrasonic vibration propagates to the region of the annular waveguide groove 1214, reflection, refraction and interference can occur at the groove wall, thereby enhancing the vibration amplitude near the cutting edge 1211 and improving the processing effect of ultrasonic-assisted stamping. The annular waveguide groove 1214 can be a closed annular groove or an annular groove with an opening, and can also include multiple arc-shaped grooves, which are spaced apart on a circle. The processing method of the annular waveguide groove 1214 can be mechanical processing, laser processing, laser etching, micro-electrical discharge machining (μ-EDM), precision grinding or other precision processing technology that can form the annular waveguide groove 1214. This application does not limit this.

[0059] It is understood that in some other possible embodiments, the number of annular waveguide slots 1214 may also be one.

[0060] In some embodiments, the spacing between two adjacent annular waveguide grooves 1214 is 0.1mm to 0.3mm, the groove depth of the annular waveguide groove 1214 is 0.1mm to 0.5mm, and the groove width of the annular waveguide groove 1214 is 0.05mm to 0.2mm. This helps to concentrate ultrasonic energy in the punching shearing region, improve the ultrasonic punching effect, and maintain the hole shape quality.

[0061] For example, the slot spacing refers to the shortest distance between the edges of two adjacent annular waveguide slots 1214. The slot spacing can be 0.1mm, 0.2mm, or 0.3mm; the slot depth can be 0.1mm, 0.15mm, 0.18mm, 0.2mm, 0.25mm, 0.3mm, 0.4mm, or 0.5mm; and the slot width can be 0.05mm, 0.1mm, 0.15mm, or 0.2mm.

[0062] It is understandable that the depths of multiple annular waveguide grooves can be the same or different; the groove spacing can be the same or different; and the groove widths of multiple annular waveguide grooves can be equal or unequal. For example, the groove depth of each annular waveguide groove gradually decreases from the center of the stamping end face to the outer edge of the stamping end face.

[0063] In some embodiments, the cross-sectional shape of the annular waveguide groove 1214 can be V-shaped, U-shaped (i.e., the bottom of the groove is an arc surface) or rectangular (the bottom of the groove is a plane). It is understood that the cross-sectional shape of the annular waveguide groove 1214 can also be trapezoidal, arc-shaped or other groove shapes that can realize the waveguide function.

[0064] In some embodiments, the surface roughness Ra of the inner wall of the annular waveguide groove 1214 may not exceed 0.4 μm, for example, it may be 0.1 μm, 0.2 μm, 0.3 μm or 0.4 μm, to reduce energy loss during ultrasonic wave propagation and improve ultrasonic energy transfer efficiency, thereby facilitating the concentration of ultrasonic energy in the punching shearing region and improving the hole shape quality. Finite element simulation results show that, compared with a punch without the annular waveguide groove 1214, when the groove depth of the annular waveguide groove 1214 is 0.15 mm to 0.25 mm, the vibration amplitude near the cutting edge 1211 can be increased by approximately 25% to 40%.

[0065] The method for manufacturing the heating mesh of this application will be described in detail below with reference to specific embodiments and comparative examples.

[0066] Example 1 The sheet material 20 to be processed is SS316L stainless steel foil with a thickness of 0.08mm. The material is in the annealed state and has a hardness of HV160~180. The effective processing area of ​​the heating mesh 30 is 20mm×10mm. The mesh 31 array is 15 columns×40 rows, with a total of 600 mesh 31. The mesh 31 is distributed in a regular array. The spacing p between two adjacent mesh 31 is 0.5mm, and the target aperture d is 0.06mm.

[0067] Based on the target aperture d≥0.05mm, the ultrasonic amplitude A is determined to be 8μm. According to the aperture spacing p and the propagation velocity parameter k=900m / s corresponding to SS316L stainless steel, the theoretical frequency is calculated using the formula f=k / (n×p), and n=60, determining the ultrasonic frequency to be approximately 30kHz. The punching end face 1213 of the punch body 121 is provided with three concentric annular waveguide grooves 1214. The groove depth of the annular waveguide grooves 1214 is 0.2mm, the groove width is 0.1mm, and the groove spacing is 0.2mm. The radius of the rounded corner 1212 of the punch body 121 cutting edge 1211 is determined according to r=αA, where α is 0.5, therefore the radius r of the rounded corner 1212 is 4μm. During the punching process, an intermittent ultrasonic punching mode is adopted, with the first set number of punches N being 120, the second set number of punches M being 5, and the punching speed being 150 punches / minute.

[0068] After processing, the heating mesh 30 was inspected. The results showed that after using the heating mesh manufacturing method provided in this application embodiment, the single-piece punching force was approximately 0.72N, which was significantly reduced compared to 1.8N without ultrasonic punching; the burr height of the mesh 31 of the obtained heating mesh 30 was 2.8μm, the roundness deviation was 1.9%, and the board warpage was 0.04mm; indicating that the heating mesh manufacturing method provided in this application embodiment, which uses ultrasonic-assisted punching, can effectively reduce the punching force, improve the hole shape accuracy, and reduce board warpage deformation.

[0069] Example 2 The material to be processed, 20, is a Ni80 nickel-chromium alloy foil with a thickness of 0.05 mm. The target aperture d of the heating mesh 30 is 0.04 mm, and the hole spacing p is 0.3 mm.

[0070] Based on the target aperture d < 0.05 mm, the ultrasonic amplitude A is determined to be 12 μm; based on the propagation velocity parameter k = 800 m / s corresponding to nickel-chromium alloy, n = 89 is taken, and the ultrasonic frequency is determined to be approximately 30 kHz. The punching end face 1213 of the punch body 121 is provided with two annular waveguide grooves 1214, with a groove depth of 0.18 mm; the radius of the rounded corner 1212 is determined according to r = αA, where α is taken as 0.4, resulting in a rounded corner radius r of 5 μm. The first set number of punches N is 80, and the second set number of punches M is 5. Before punching, the sheet material 20 to be processed is preheated at 120°C for 10 seconds to further improve the material's plasticity.

[0071] Processing results show that the burr height of the mesh 31 of the heating mesh 30 is 4.2 μm, the roundness deviation is 2.5%, and the continuous service life of the punch can exceed 250,000 strokes. This indicates that the heating mesh manufacturing method provided in this application embodiment is applicable to high-hardness nickel-chromium alloy materials and effectively improves the service life of the punch and the quality of the hole shape.

[0072] Example 3 The substrate 20 to be processed is a Ti-6Al-4V titanium alloy foil with a thickness of 0.05mm. The target aperture d of the heating mesh 30 is 0.05mm and the hole spacing p is 0.4mm.

[0073] The ultrasonic amplitude A is determined to be 12 μm based on the target aperture d. Based on the propagation velocity parameter k = 1100 m / s for titanium alloy, and taking n = 92, the ultrasonic frequency is determined to be approximately 30 kHz. Due to the high yield strength, low elastic modulus, and poor thermal conductivity of titanium alloy, to improve the transmission efficiency of ultrasonic vibration in the punch body 121, and considering that the elastic modulus of titanium alloy is only about 55% of that of steel, resulting in significant vibration attenuation, it is necessary to compensate for the amplitude by deepening the inner ring waveguide grooves. This ensures that the cutting edge area of ​​the stamping end face still has sufficient vibration amplitude. The stamping end face 1213 of the punch body 121 is provided with three concentric annular waveguide grooves 1214. From the center of the stamping end face towards the outer edge, the groove depths of each annular waveguide groove are 0.25 mm, 0.15 mm, and 0.10 mm, respectively, and the groove width is 0.12 mm for all grooves. The radius of the fillet 1212 is determined by r=αA, where α is taken as 0.4, and the radius r of the fillet 1212 is approximately 5μm.

[0074] Intermittent ultrasonic operation is employed during the punching process, with a first set number of cycles N of 60 and a second set number of cycles M of 5, to reduce punch temperature rise and improve processing stability. Before punching, the sheet material 20 to be processed is preheated to 200℃~250℃ and held at that temperature for 15s~20s to improve the plasticity of the titanium alloy and reduce the punching load. During punching, a small amount of volatile organic solvent lubricant is applied between the punch body 121 and the sheet material 20 to be processed. The lubricant can be an ethanol-based lubricant, an isopropanol-based lubricant, or other volatile stamping lubricant. The lubricant can completely evaporate within about 5s after punching to reduce processing residue and reduce friction. The cutting edge 1211 of the punch body 121 is coated with a chemical vapor deposition (CVD) diamond coating with a thickness of 5μm~10μm to improve wear resistance and service life.

[0075] Processing results show that under ultrasonic-assisted stamping conditions, the punching force is reduced by approximately 40%–50% compared to conditions without ultrasonic treatment. The burr height of the mesh 31 of the heating mesh 30 is controlled within 4 μm, the hole roundness deviation does not exceed 3.5%, the plate warpage does not exceed 0.06 mm, and the continuous service life of the punch can reach 150,000–200,000 cycles. Furthermore, no obvious oxidation or discoloration is observed on the surface of the processed heating mesh 30. This indicates that the heating mesh manufacturing method provided in this application embodiment is applicable to the micro-hole processing of high-strength titanium alloy materials, effectively reducing the punching load and improving the punch service life while ensuring hole shape accuracy and surface quality.

[0076] Table 5:

[0077] Table 5 is a comparison table of the performance of ultrasonic-assisted stamping and mechanical stamping. From Table 5 and... Figure 8 As can be seen, compared with the comparative mechanical stamping process, the ultrasonic-assisted stamping method for manufacturing the heating mesh in this embodiment can significantly reduce the punching force, hole edge burr height, hole roundness deviation, and sheet warpage, thereby improving the punch life and product yield. Specifically, the average lifespan of the punch body 121 is increased by 3.5 times, the hole edge burr height is reduced by 70%, the hole roundness deviation is reduced by 67%, and the sheet warpage is reduced by 73%. This demonstrates that the ultrasonic-assisted stamping method for manufacturing the heating mesh in this embodiment can effectively improve the processing quality of the heating mesh 30 and enhance the stability and production efficiency of continuous stamping.

[0078] See Figure 9 As shown, the ultrasonic punching device 10 provided in this embodiment is used for ultrasonic-assisted punching of the sheet metal 20 to be processed. The ultrasonic punching device 10 includes a punching frame 11, a punch assembly 12, and a controller 13; the punch assembly 12 is mounted on the punching frame 11, and the punch assembly 12 includes a punch body 121 and an ultrasonic transducer 122 acoustically coupled to the punch body 121; the controller 13 is electrically connected to the ultrasonic transducer 122. The controller 13 is used to execute the heating mesh manufacturing method in any of the above embodiments to punch holes in the sheet metal 20 to be processed through the punch body 121, so as to obtain the heating mesh 30. The ultrasonic punching device 10 has the same technical effects as the heating mesh manufacturing method provided in the foregoing embodiments, and will not be described again here.

[0079] See Figure 9 As shown, in some embodiments, the ultrasonic stamping device 10 further includes a force sensor 14, a die 15, and a worktable 16. The punch assembly 12 also includes an amplitude transformer 123; the stamping frame 11 serves as the supporting structure of the entire machine, including a crossbeam 112 and a frame body 111. The crossbeam 112 is mounted on the upper part of the frame body 111 and is used to mount the ultrasonic transducer 122; the worktable 16 is located below the frame body 111 and is used to mount the die 15 and support the sheet metal 20 to be processed. The die 15 is fixedly mounted on the worktable 16, forming a punching station corresponding vertically to the punch body 121. The driving mechanism of the stamping frame 11 is used to drive the punch body 121 to reciprocate in the vertical direction. The driving mechanism can adopt common structures such as a crank-slider mechanism, a servo pressure mechanism, a pneumatic drive mechanism, or a hydraulic drive mechanism, which are not limited in this embodiment.

[0080] The controller 13 is used to adjust the ultrasonic frequency and ultrasonic amplitude according to the processing parameters. The controller 13 can be a programmable logic controller (PLC), industrial computer, microcontroller, digital signal processor (DSP), field-programmable gate array (FPGA), or other control unit capable of implementing control functions. The controller 13 is electrically connected to the ultrasonic transducer 122 and is used to control the start and stop of the ultrasonic transducer 122, and to control the operating parameters such as the frequency, power, amplitude, and duration of ultrasonic vibration, so as to cooperate with the punch body 121 to complete ultrasonic-assisted punching processing.

[0081] For example, the controller 13 acquires the processing parameters of the heating mesh 30, determines the ultrasonic amplitude based on the target aperture, determines the ultrasonic frequency based on the hole spacing between adjacent mesh holes 31, and outputs a corresponding control signal to the ultrasonic transducer 122, causing the punch body 121 to perform ultrasonic punching according to the set parameters. During the processing, the controller 13 can also switch the ultrasonic working state according to a preset program, so that the punching operation adopts an alternating punching mode, that is, after controlling the punch body 121 to continuously perform ultrasonic punching for a first set number of times, it continuously performs non-ultrasonic punching for a second set number of times, and the above processing process is repeated.

[0082] See Figure 9 As shown, in some embodiments, the ultrasonic transducer 122 is mounted below the crossbeam 112. The ultrasonic transducer 122 includes a piezoelectric ceramic stack 1221, which is electrically connected to the controller 13. The ultrasonic transducer 122 can be a piezoelectric ultrasonic transducer 122 or a magnetostrictive ultrasonic transducer 122; for example, the piezoelectric ultrasonic transducer 122 can use piezoelectric ceramic (PZT) as the piezoelectric material.

[0083] The piezoelectric ceramic stack 1221 generates axial mechanical vibration under the excitation of an ultrasonic driving signal, which is transmitted to the punch body 121 via the amplitude transformer 123. One end of the amplitude transformer 123 is connected to the ultrasonic transducer 122, and the other end is connected to the punch body 121. It is used to transmit ultrasonic vibration and adjust the vibration amplitude so that the punch body 121 obtains axial ultrasonic vibration with a set amplitude. Exemplarily, the amplitude transformer 123 can adopt a conical or stepped structure, which is not limited in this embodiment.

[0084] See Figure 9 As shown, in some embodiments, the punch body 121 is located at the lower end of the amplitude transformer 123, fixedly connected to the amplitude transformer 123, and located above the die 15. The sheet material 20 to be processed is placed above the die 15 and can be positioned by a pressure plate, positioning pin, clamping mechanism, vacuum adsorption mechanism or other positioning mechanism. This application embodiment does not limit this.

[0085] The punch body 121 can be made of cemented carbide (WC-Co); it is understood that the material of the punch body 121 can also be selected according to the material, thickness and production requirements of the heating mesh to be processed, such as high-speed steel (HSS), polycrystalline diamond (PCD), cubic boron nitride (CBN), ceramic materials, or composite materials with a surface having a chemical vapor deposition (CVD) diamond coating or other wear-resistant coatings. This application does not limit this.

[0086] It is understood that the structural parameters and dimensional parameters of the annular waveguide groove 1214 on the stamping end face 1213 of the punch body 121, as well as the radius of the rounded corner 1212 of the cutting edge 1211 of the punch body 121, can be found in the relevant descriptions in the aforementioned embodiments of the heating mesh manufacturing method, and will not be repeated here.

[0087] Combination Figure 10 and Figure 11 As shown, in some embodiments, the punch body 121 has a cooling channel 1215, which extends axially through both axially opposite end faces of the punch body 121. One end of the cooling channel 1215 is connected to an external cooling medium supply device, and the other end extends to the stamping end face 1213 of the punch body 121, forming a cooling medium outlet on the stamping end face 1213. A solenoid valve is installed on the pipeline between the external cooling medium supply device and the cooling channel 1215, and the solenoid valve is electrically connected to the controller 13. The controller 13 controls the cooling channel 1215 to work in conjunction with the aforementioned intermittent ultrasonic mode using an intermittent cooling mechanism.

[0088] For example, the cooling medium can be a gaseous or liquid medium, such as compressed air, compressed nitrogen, compressed carbon dioxide, inert gas, water, coolant, or other fluids capable of cooling. This application does not limit this. During the ultrasonic punching stage of the punch body 121 performing the first set number N times, the controller 13 controls the solenoid valve to close, stopping the supply of cooling medium to the cooling channel 1215 to avoid interference of the cooling medium flow with the energy distribution of the ultrasonic vibration field. During the non-ultrasonic punching stage of the punch body 121 performing the second set number M times, the controller 13 controls the solenoid valve to open, and the external cooling medium enters the interior of the punch body 121 through the cooling channel 1215 and is discharged from the cooling medium outlet of the punching end face 1213, carrying away the heat accumulated in the punch body 121 and the cutting edge 1211 area during the ultrasonic punching stage. Through the intermittent cooling mechanism described above, the punch body 121 can be periodically cooled without affecting the ultrasonic stamping effect, and the temperature rise of the ultra-thin sheet can be controlled within a safe range (e.g., not greater than 55 ℃), effectively preventing the sheet from entering the sensitization temperature range due to overheating and causing performance degradation.

[0089] In some embodiments, the lubrication method used in the punching operation is not limited to spraying volatile organic solvents, but may also use a solid lubricating layer pre-formed on the surface of the punch body 121, such as a molybdenum disulfide (MoS2) coating, a graphite coating, or other lubricating coatings with friction-reducing and anti-adhesion effects. This application does not limit this method.

[0090] It is understandable that during the non-ultrasonic punching process, liquid nitrogen micro-jet cooling or heat pipe heat dissipation structure can also be used to cool the punch body 121, and this application does not limit this.

[0091] Combination Figure 9 As shown, in some embodiments, the force sensor 14 is disposed on the force transmission path of the stamping frame 11 to detect the punching force information during the punching process of the punch body 121. The force sensor 14 sends the detected force signal to the controller 13. The controller 13 receives the force signal and adjusts the ultrasonic frequency, ultrasonic amplitude, or punching parameters according to the force signal. The force signal can also be used as a data source for monitoring the processing status. The punching force is the force applied by the punch body 121 to the sheet metal 20 to be processed, which is also the amount actually detected by the force sensor 14. When the punching force detected by the force sensor 14 is greater than a preset threshold, it indicates that the current processing resistance is large or the punch is showing a wear trend. The controller 13 controls the ultrasonic transducer 122 to increase the ultrasonic amplitude A or ultrasonic frequency f to reduce the punching force. When the punching force returns to the normal range, the ultrasonic amplitude is adjusted to the initial set value.

[0092] During operation, the controller 13 controls the ultrasonic transducer 122 to output ultrasonic drive signals with corresponding frequency and amplitude according to the preset processing program. The piezoelectric ceramic stack 1221 generates axial mechanical vibration under the excitation of the ultrasonic drive signal, and transmits it to the punch body 121 through the amplitude transformer 123. The drive mechanism of the stamping frame 11 drives the punch body 121 to reciprocate along the stamping direction, so that the punch body 121 cooperates with the die 15 to complete the punching of the plate under the combined action of mechanical stamping motion and axial ultrasonic vibration, and completes the processing of each mesh 31 in sequence according to the preset path. Then, through other processing steps, such as cutting, the heating mesh 30 is formed.

[0093] In some embodiments, the vibration direction of the ultrasonic vibration can coincide with the axis of the punch body 121, or it can form a preset angle with the axis of the punch body 121. For example, the preset angle is no greater than 5°; in other embodiments, the preset angle can be 0° to 15°, and the structural parameters of the annular waveguide groove 1214 can be adjusted accordingly to maintain the ultrasonic wave guiding and vibration transmission effect.

[0094] See Figure 12As shown, the heating mesh 30 provided in this embodiment is manufactured using the heating mesh manufacturing method provided in any of the above embodiments; or, it is manufactured using the ultrasonic stamping device 10 provided in any of the above embodiments. The heating mesh 30 has the same technical effects as the heating mesh manufacturing method provided in the foregoing embodiments, and will not be described again here. For example, the heating mesh 30 has a plurality of mesh holes 31 arranged in an array; the mesh holes 31 are through holes.

[0095] It should be understood that, in the embodiments of this application, unless otherwise expressly specified and limited, the terms "connection," "fixed connection," "contact," etc., should be interpreted broadly. Those skilled in the art can understand the specific meanings of the various terms in the embodiments of this application according to the specific circumstances.

[0096] For example, the "connection" can be a fixed connection, a rotating connection, a flexible connection, a sliding connection, a one-piece molding, an electrical connection, a contact connection, or other connection methods; it can be a direct connection, or an indirect connection through an intermediate medium, or a connection within two components or an interaction between two components.

[0097] For example, a "fixed connection" can be a component that can be directly or indirectly fixedly connected to another component; a fixed connection can include mechanical connection, welding, bonding or integral molding, etc., wherein mechanical connection can include riveting, bolting, threaded connection, keying, snap-fit ​​connection, locking connection, plugging, etc., and bonding can include adhesive bonding and solvent bonding, etc.

[0098] It should also be understood that the “parallel” or “perpendicular” described in the embodiments of this application can be understood as “approximately parallel” or “approximately perpendicular”.

[0099] It should also be understood that the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of technical features indicated. Features specified as "first" or "second" may explicitly or implicitly include one or more of that feature.

[0100] In the embodiments of this application, unless otherwise expressly specified and limited, "above" or "below" the second feature can mean that the first feature and the second feature are in direct contact, or that the first feature and the second feature are in indirect contact through an intermediate medium. Furthermore, "above," "on top of," and "over" the second feature can mean that the first feature is directly above or diagonally above the second feature, or simply that the first feature is at a higher horizontal level than the second feature. "Below," "below," and "under" the second feature can mean that the first feature is directly below or diagonally below the second feature, or simply that the first feature is at a lower horizontal level than the second feature.

[0101] It should also be understood that the terms “length,” “width,” “up,” “down,” “front,” “back,” “left,” “right,” “vertical,” “horizontal,” “top,” “bottom,” “inner,” and “outer,” etc., indicate the orientation or positional relationship (if any) based on the orientation or positional relationship shown in the accompanying drawings. They are used only for the convenience of describing this application and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this application.

[0102] The above description is merely a specific embodiment of this application, but the scope of protection of this application is not limited thereto. Any variations or substitutions that can be easily conceived by those skilled in the art within the technical scope disclosed in this application should be included within the scope of protection of this application. Therefore, the scope of protection of this application should be determined by the scope of protection of the claims. In summary, the above description is merely a preferred embodiment of the technical solution of this application and is not intended to limit the scope of protection of this application. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of this application should be included within the scope of protection of this application.

Claims

1. A method for manufacturing a heating mesh, characterized in that, include: The ultrasonic amplitude applied to the punch body of the ultrasonic punching device is determined based on the target aperture of the heating mesh. The ultrasonic frequency of the ultrasonic stamping device is determined based on the spacing between two adjacent mesh openings in the heating mesh. The punch body is driven to punch holes in the sheet metal to be processed, so as to form the mesh of the heating mesh on the sheet metal to be processed; The punching operation adopts an alternating punching mode, which includes: the punch body alternately performing a first set number of ultrasonic punchings and a second set number of non-ultrasonic punchings; during the ultrasonic punching, the punch body performs ultrasonic vibration according to the ultrasonic frequency and the ultrasonic amplitude.

2. The method for manufacturing a heating mesh according to claim 1, characterized in that, The step of determining the ultrasonic amplitude applied to the punch body of the ultrasonic punching device based on the target aperture of the heating mesh includes: When the target aperture d is less than 0.05 mm, the ultrasonic amplitude A is determined to be greater than 10 μm and less than or equal to 15 μm; When the target aperture d is not less than 0.05 mm, the ultrasonic amplitude A is determined to be greater than or equal to 5 μm and less than or equal to 10 μm.

3. The method for manufacturing a heating mesh according to claim 1, characterized in that, The hole spacing p and the ultrasonic frequency f satisfy the following relationship: f=k / (n×p), where n is a positive integer and 20kHz≤f≤40kHz, and k is the propagation speed parameter corresponding to the material of the plate to be processed.

4. The method for manufacturing a heating mesh according to claim 3, characterized in that, When the material of the plate to be processed is stainless steel, the propagation velocity parameter k is 800m / s~1100m / s; When the material of the plate to be processed is a nickel-chromium alloy, the propagation velocity parameter k is 700m / s~1000m / s; When the material of the plate to be processed is titanium alloy, the propagation speed parameter k is 900m / s~1300m / s.

5. The method for manufacturing a heating mesh according to any one of claims 1-4, characterized in that, After determining the ultrasonic amplitude applied to the punch body of the ultrasonic punching device, and before driving the punch body to perform a punching operation on the sheet metal to be processed, the heating mesh manufacturing method further includes: The radius of the fillet of the cutting edge of the punch body is determined based on the ultrasonic amplitude.

6. The method for manufacturing a heating mesh according to claim 5, characterized in that, The fillet radius r and the ultrasonic amplitude A satisfy the following relationship: r = αA, where α is the fillet coefficient and 0.3 ≤ α ≤ 0.

6.

7. The method for manufacturing a heating mesh according to any one of claims 1-4, characterized in that, The first set number of times N and the second set number of times M satisfy the following relationship: N / M≥ 15.

8. The method for manufacturing a heating mesh according to any one of claims 1-4, characterized in that, The first set number of times N is 50 to 200 times, and the second set number of times M is 3 to 10 times.

9. An ultrasonic stamping device, characterized in that, include: stamping machine frame; A punch assembly is mounted on the stamping frame. The punch assembly includes a punch body and an ultrasonic transducer acoustically coupled to the punch body. The punch body has an annular waveguide groove on its stamping end face. A controller, electrically connected to the ultrasonic transducer, is used to determine the ultrasonic amplitude based on the target aperture of the heating mesh, determine the ultrasonic frequency based on the spacing between two adjacent mesh openings in the heating mesh, and output a control signal to the ultrasonic transducer to drive the punch body to perform ultrasonic punching on the material to be processed in an alternating punching mode. The alternating punching mode includes the punch body alternately performing a first set number of ultrasonic punchings and a second set number of non-ultrasonic punchings.

10. The ultrasonic stamping device according to claim 9, characterized in that, The number of the annular waveguide grooves is multiple, and the multiple annular waveguide grooves are arranged concentrically. The spacing between two adjacent annular waveguide slots is 0.1mm to 0.3mm, the depth of the annular waveguide slot is 0.1mm to 0.5mm, and the width of the annular waveguide slot is 0.05mm to 0.2mm.

11. The ultrasonic stamping device according to claim 9 or 10, characterized in that, The cutting edge of the punch body is provided with a rounded corner radius corresponding to the ultrasonic amplitude; The fillet radius r of the cutting edge and the ultrasonic amplitude A satisfy the following relationship: r = αA, where α is the fillet coefficient and 0.3 ≤ α ≤ 0.

6.

12. A heating mesh, characterized in that, The heating mesh is manufactured using the heating mesh manufacturing method as described in any one of claims 1-8; Alternatively, it can be produced using the ultrasonic stamping apparatus as described in any one of claims 9-11.

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