Ultrasonic additive and subtractive integrated manufacturing equipment
By integrating the main frame, spindle, and additive and subtractive manufacturing structures, the ultrasonic additive and subtractive integrated manufacturing equipment solves the problems of low efficiency and reduced accuracy of traditional UAM equipment, and realizes efficient and accurate manufacturing of complex metal parts, which is applicable to aerospace, automotive manufacturing and medical device fields.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Utility models(China)
- Current Assignee / Owner
- Filing Date
- 2025-01-10
- Publication Date
- 2026-03-24
AI Technical Summary
Traditional UAM equipment uses a split processing method, which leads to problems such as low work efficiency, reduced product accuracy, and wasted production costs.
Design an ultrasonic additive and subtractive manufacturing equipment that integrates a main frame, main shaft, additive structure and subtractive structure, and achieves unified control of the additive and subtractive processes through a control module, including a cutting unit, foil feeding unit, ultrasonic welding unit and milling tool, and has fault diagnosis and early warning functions.
It enables efficient and precise manufacturing of complex metal parts, improves manufacturing efficiency and part quality, overcomes the limitations of traditional manufacturing processes, and is applicable to fields such as aerospace, automobile manufacturing, and medical devices.
Smart Images
Figure CN224026962U_ABST
Abstract
Description
TECHNICAL FIELD
[0001] The utility model relates to additive and subtractive manufacturing technical field especially an ultrasonic additive and subtractive integrated manufacturing equipment. BACKGROUND
[0002] Ultrasonic additive manufacturing (UAM) as a new additive manufacturing technology, its core principle is to use high-frequency ultrasonic vibration (frequency range commonly between 20kHz-40kHz) to cause material to occur intense friction and intermolecular interaction in microcosmic level, thereby making workpiece realize solid-state welding (below 50% of material melting point) under pressure. In electrical and electronic equipment manufacturing field, ultrasonic welding is commonly used for sealing small electronic components and circuit board assembly, ensuring the reliability and stability of electrical connection; in new energy automobile manufacturing industry, it is widely used in the welding of battery element tab, and can be used for the assembly of plastic parts such as automobile interior parts, which can realize efficient and reliable connection, improve product appearance quality and meet the corresponding technical requirements; in the field of aerospace, ultrasonic welding technology can be used to process various aluminum light alloy materials, meeting the requirements of high strength and light weight of structural parts. A typical ultrasonic welding system works cooperatively by multiple key components, wherein the press machine serves as a device for providing stable pressure, which can ensure that the workpiece is tightly attached during the welding process and guarantee the welding quality; the base or anvil provides a stable support platform for the workpiece and helps guide and transmit ultrasonic vibration; the ultrasonic welding head is the core vibration part of the system, which is responsible for converting electrical energy into high-frequency mechanical vibration by piezoelectric transducer, transmitting the vibration to the ultrasonic welding head through the amplitude changer, and finally conducting the vibration to the workpiece through the welding head.
[0003] When building a part, first, thin metal or non-metal strip (usually with a thickness of tens to hundreds of microns) is used as raw material, and the metal strip is welded layer by layer under the action of pressure by using the ultrasonic welding head to form the basic shape of the part. After each layer of welding is completed, the milled cutter is controlled by the CNC system to mill the welded structure to remove excess material and form accurate features such as internal channels, grooves, threads, etc., while trimming the part surface to ensure its flatness and accuracy requirements, so the UAM technology can manufacture metal parts with complex internal structure and high-precision surface quality.
[0004] Traditional UAM equipment generally adopts split processing mode, i.e. the UAM equipment is used to ultrasonically weld into a simple shape, and then moved to a precise CNC machine tool for fine processing, which greatly increases the work efficiency, while repeated positioning of the workpiece will reduce the accuracy of the product, which not only reduces the product quality, but also causes waste of production cost. UTILITY MODEL CONTENTS
[0005] In order to overcome the above problems existing in the prior art, the utility model provides an ultrasonic additive and subtractive integrated manufacturing equipment.
[0006] The utility model discloses a technical scheme that solves its technical problem: an ultrasonic additive and subtractive integrated manufacturing equipment, including main frame, main shaft, additive structure, subtractive structure, control module, the main shaft vertical installation is in one side of main frame, the subtractive structure installs on the main shaft and can move up and down along the main shaft, the additive structure installs in the right side of main shaft, the main frame upper surface is provided with the worktable that can move in x -axis and y -axis direction,
[0007] The additive structure includes a cutting unit, a foil feeding unit and an ultrasonic welding unit, the cutting unit is used for cutting a foil strip, and the foil feeding unit is used for continuously providing the ultrasonic welding unit with a metal or non-metal foil strip.
[0008] The subtractive structure includes a milling tool, and the control module is used for receiving a three-dimensional model of a part and controlling the additive structure and the subtractive structure.
[0009] The ultrasonic additive and subtractive integrated manufacturing equipment has the heating wires arranged horizontally and vertically in the worktable.
[0010] The ultrasonic additive and subtractive integrated manufacturing equipment has the ultrasonic welding unit including a connecting plate, ultrasonic transducers, an ultrasonic amplitude transformer and an ultrasonic welding head, the connecting plate is connected with the main shaft, the ultrasonic transducers are located on both sides of the ultrasonic amplitude transformer, and the ultrasonic welding head is located at the middle position of the ultrasonic amplitude transformer.
[0011] The ultrasonic additive and subtractive integrated manufacturing equipment has the ultrasonic welding head with a surface roughness Ra=25 μm.
[0012] The ultrasonic additive and subtractive integrated manufacturing equipment has the foil feeding unit including a foil raw material wheel, a tensioning wheel, a limiting wheel, a conveying wheel and a conveying card, the tensioning wheel is provided with a tension sensor for monitoring the tension of the foil in real time, the limiting wheel is used for guiding the foil into the conveying wheel and limiting the outflow of the foil, the conveying wheel is used for controlling the feeding speed of the foil, and the conveying card is used for accurately feeding the foil to the position below the ultrasonic welding unit.
[0013] The ultrasonic additive and subtractive integrated manufacturing equipment has the conveying wheel driven to rotate by a motor, the motor is controlled by the control module, and the conveying wheel is provided with polyurethane limiting blocks on the surface.
[0014] The utility model discloses beneficial effect is, the utility model discloses in the whole ultrasonic additive and subtractive manufacturing process, the close cooperation of each part of equipment, by the unified accurate control of control module, not only can realize real -time monitoring and parameter adjustment to processing, still possess fault diagnosis and early warning function. The utility model discloses can efficiently, accurately realize the manufacturing of complex metal parts, give full play to the advantage of ultrasonic additive manufacturing and subtractive machining, overcome the limitation of traditional manufacturing process, provide high -performance, high -precision metal part manufacturing solution for the field such as aerospace, automobile manufacturing, medical instrument. BRIEF DESCRIPTION OF DRAWINGS
[0015] Figure 1 It is the utility model schematic diagram;
[0016] Figure 2 It is the utility model workbench schematic diagram, wherein (a) is workbench plan view;B) is workbench perspective view;
[0017] Figure 3 It is the utility model ultrasonic welding module schematic diagram.
[0018] Among them, 1. main shaft, 2. ultrasonic welding unit, 3. cutting unit, 4. foil belt raw material wheel, 5. tensioning wheel, 6. limit wheel, 7. conveying wheel, 8. conveying card, 9. workbench.
[0019] 21. Connecting plate, 22. Ultrasonic transducer, 23. Ultrasonic welding head, 24. Ultrasonic amplitude rod. DETAILED DESCRIPTION
[0020] In order to make those skilled in the art better understand the technical scheme of the utility model, the utility model is explained in detail below in combination with the drawings and specific embodiments.
[0021] As Figure 1 Indicated, the embodiment discloses a kind of ultrasonic additive and subtractive integrated manufacturing equipment, including main frame, main shaft 1, additive structure, subtractive structure, control module, the main shaft 1 is vertically installed in main frame side, the subtractive structure is installed on main shaft 1 and can move up and down along main shaft, the additive structure is installed in main shaft right side, the upper surface of main frame is provided with workbench 9 that can move in x axis and y axis direction. The subtractive structure includes milling tool, and the control module is used to receive part three-dimensional model and control additive structure and subtractive structure work.
[0022] Main frame is used as the basis support structure of milling tool, is made of high-strength metal material, with enough rigidity and stability, to ensure that equipment does not obviously deform in manufacturing process. The z-axis guide rail system of accurate construction inside main frame provides high-precision guidance and support for subsequent movement of main shaft.
[0023] The spindle, as a key moving component of the milling tool, is manufactured using precision machining processes and its surface is treated specially (such as quenching, grinding, etc.) to improve hardness and surface finish, ensuring precision and stability during high-speed rotation and frequent axial movement. The spindle is compatible with various standard milling tools, achieving reliable connection with the milling tool through high-precision taper fitting (such as common BT, CAT taper systems). The spindle is internally designed with cooling channels that can introduce cooling liquid during operation, effectively removing heat generated by high-speed rotation and cutting, preventing spindle deformation or damage due to overheating. The spindle is connected to the z-axis motor through a high-precision ball screw nut pair, and the z-axis motor is driven by the control module to achieve fast and accurate movement in the z-axis direction, with a positioning accuracy of ±0.005mm or even higher.
[0024] The spindle plays a crucial role in the working process of the milling tool, with functions including tool installation (different types of milling cutters such as end mills, face mills, ball nose mills, etc.), rotational drive (motor speed and torque are transmitted to the spindle through belt drive, gear drive or direct drive, and the spindle accurately transmits rotational motion to the milling cutter), motion control (the spindle can not only rotate but also move along the z-axis direction within a certain range, allowing the milling cutter to cut the workpiece in different depth directions. This z-axis motion control combined with the worktable movement in x and y directions allows the milling cutter to cut the workpiece according to the predetermined machining path in three-dimensional space), precision guarantee (high-precision spindles ensure that the milling cutter blade always moves on an accurate circle during rotation, resulting in uniform cutting thickness and reducing machining errors), power transmission (the spindle can effectively transmit the motor output power and torque to the milling cutter, providing appropriate power according to machining requirements. Different specifications and models of milling spindles have different power and torque characteristics to meet various types and sizes of machining tasks), and many other aspects.
[0025] 9 is a worktable, which is located below the main shaft and can move freely in the x-axis and y-axis directions, covering the entire worktable surface, providing a wide operating space for part processing. The worktable 9 below the main shaft is also made of high-strength metal material, and its surface is finely ground to ensure flatness and roughness requirements. The worktable below is connected to the x-axis and y-axis motors through linear guides, forming a high-precision planar motion system. The x-axis and y-axis motors can drive the worktable to achieve rapid and accurate positioning and movement in the x-axis and y-axis directions under the coordinated control of the control system. The movement speed can be adjusted according to the processing requirements, with a maximum speed of several meters per minute, and the positioning accuracy can also reach the ±0.005mm level. The size of the worktable is determined according to the design specifications of the equipment. Generally, the worktable size of large equipment can reach several square meters, capable of carrying larger size and weight workpieces for processing.
[0026] In specific embodiments, heating wires are arranged horizontally and vertically inside the worktable, as shown in Figure 2 These heating wires are connected to the control center module through PLC, which can provide a certain preset temperature for the welding process to meet the processing requirements of more materials. The entire processing platform main frame serves as the basic support structure of the ultrasonic welding manufacturing equipment, not only providing a stable installation platform for the main shaft and worktable, but also bearing the weight of the entire equipment and various forces generated during the work process.
[0027] In this embodiment, the control module uses an advanced industrial control computer or programmable logic controller (PLC) as the core control unit, equipped with high-precision motion control cards and sensor interface cards. Before the manufacturing process begins, the operator imports the three-dimensional model of the part into the control module, and selects different types of foil according to the required part structure, and selects appropriate welding parameters such as welding pressure, ultrasonic frequency, ultrasonic amplitude, welding speed, and worktable temperature. During the manufacturing process, the control module monitors various state parameters of the equipment in real time, such as the position of the main shaft, the position of the worktable, the vibration parameters of the welding head, the milling force, the temperature, etc., and dynamically adjusts the operating state of the equipment according to these parameters. For example, during the additive welding process, if the welding quality is detected to be abnormal (such as insufficient welding strength, discontinuous weld, etc.), the control module will immediately adjust the welding parameters (such as increasing the vibration energy, adjusting the welding pressure, etc.); in the subtractive milling process, if the tool wear exceeds the set threshold, the control module will automatically replace the tool or adjust the milling parameters to ensure the processing accuracy. At the same time, the control module also has a human-machine interface, through which the operator can view the progress of the manufacturing process and the state parameters of the equipment in real time, and can manually intervene in the manufacturing process as needed, such as pausing, adjusting parameters, switching processing modes, etc. Through this control module, seamless switching and collaborative work of additive manufacturing and subtractive manufacturing processes on the same equipment are realized, greatly improving the manufacturing efficiency and part quality.
[0028] In this embodiment, the additive structure includes a cutting unit 3, a foil feeding unit, and an ultrasonic welding unit 2. The cutting unit 3 is equipped with high-strength quenched steel as a blade for cutting the foil strip. The foil feeding unit is used to continuously supply metal or non-metal foil strips to the ultrasonic welding unit. The foil feeding unit includes a foil strip material wheel 4, a tensioning wheel 5, a limiting wheel 6, a conveying wheel 7, and a conveying clamp 8. The foil strip material wheel 4 is equipped with a buckle for clamping the raw foil roll, from which the raw foil strip is continuously fed outwards. The tensioning wheel is equipped with a tension sensor that monitors the foil strip tension in real time and feeds the information back to the control module interface. The limiting wheel 6 is used to guide the foil strip into the conveyor wheel and restrict the foil strip from flowing outwards. The conveyor wheel 7 is used to control the feed speed of the foil strip. The conveyor wheel is driven to rotate by a motor, which is connected to the control module. The operator can change the feed speed of the foil strip through the control module. The conveyor wheel is embedded with polyurethane material, which is a polymer material with high friction, high wear resistance, and high elasticity, which facilitates clamping the foil strip and conveying it to the predetermined position. The conveyor clip 8 is used to accurately deliver the foil strip below the ultrasonic welding unit.
[0029] In this embodiment, the ultrasonic welding unit 2 has the following structure: Figure 3 As shown, it specifically includes a connecting plate 21, an ultrasonic transducer 22, an ultrasonic amplitude transformer 24, and an ultrasonic welding head 23. The connecting plate 21 is connected to the main shaft 1. The ultrasonic transducer 22 is located on both sides of the ultrasonic amplitude transformer 24, and the ultrasonic welding head 23 is located in the middle of the ultrasonic amplitude transformer 24. The ultrasonic welding head is made of high wear-resistant materials such as tungsten steel, or it can be made by laser cladding of a high-hardness coating, such as cladding a tungsten-chromium alloy coating on a titanium alloy surface. The surface has a certain roughness, with a surface roughness Ra=25μm.
[0030] In this system, the additive and subtractive manufacturing structures achieve a close collaborative working relationship through the spindle. The entire additive structure is mounted on the right side of the spindle and can move with the spindle in the z-axis direction. At the same time, the movement of the worktable in the x and y-axis directions can accurately position the part below the ultrasonic welding assembly, realizing additive welding processing of the part. Simultaneously, the processed workpiece can be moved below the spindle for corresponding milling and reduction operations.
[0031] In the additive manufacturing process, the foil tape is accurately transported from the foil tape raw material wheel 4 to the working area below the ultrasonic welding head through the tensioning wheel 5, the limiting wheel 6, the conveying wheel 7 and the conveying card 8. The conveying wheel 7 can accurately control the feeding speed and the feeding amount of the foil tape according to the preset welding parameters (such as welding speed, welding pressure, foil tape thickness, etc.) under the control of the control module. After receiving the high-frequency ultrasonic vibration signal, the ultrasonic welding head transmits the vibration energy to the foil tape, so that the foil tape is solidly welded with the welded part (such as the substrate or the last welded layer) under the joint action of pressure and ultrasonic. During the welding process, the vibration frequency, amplitude and applied pressure of the welding head are monitored and adjusted in real time through the control system to ensure the stability and consistency of the welding quality. As the welding process continues, the metal foil tape is stacked layer by layer, and gradually forms a three-dimensional shaped part entity. After each layer of welding is completed, according to the design requirements of the part, the control module can selectively pause the welding process, start the milling operation, finely process the current layer, and then continue the welding of the next layer, and so on, until the entire additive manufacturing process of the part is completed.
[0032] When subtractive manufacturing (milling processing) is needed, the control module drives the milling tool to move in the z-axis direction, and positions the milling tool (such as a milling cutter, a drill, a boring cutter, etc.) mounted on the spindle above the part to be processed. The workbench moves the part to the machining path of the milling tool under the drive of the x-axis and y-axis motors. During the milling process, the milling tool rotates at high speed (the rotation speed can be adjusted between thousands of revolutions per minute and tens of thousands of revolutions per minute according to the machining material and tool type), and the workbench and the milling tool move cooperatively according to the preset milling path and machining parameters (such as feed speed, cutting depth, cutting width, etc.), to realize the accurate milling processing of the part. Through multiple milling operations in different directions and depths, the excess material on the part can be removed to form various complex shape features, such as internal cavities, external contours, threads, keyways, etc., and the surface of the part can be finely finished to meet the design requirements of the dimensional accuracy and surface roughness.
[0033] The above embodiments are only exemplary embodiments of the present application and are not used to limit the present application. Those skilled in the art can make various modifications or equivalent replacements to the present application within the spirit and protection scope of the present application, and such modifications or equivalent replacements should also be considered to fall within the protection scope of the present application.
Claims
1. An ultrasonic additive-subtractive integrated manufacturing apparatus, characterized by comprising: The application relates to a 3D printing device, which comprises a main frame, a main shaft, an additive structure, a subtractive structure and a control module, the main shaft is vertically installed on one side of the main frame, the subtractive structure is installed on the main shaft and can move up and down along the main shaft, the additive structure is installed on the right side of the main shaft, and the upper surface of the main frame is provided with a workbench which can move in the x-axis and y-axis directions. The additive structure comprises a cutting unit, a foil feeding unit and an ultrasonic welding unit, the cutting unit is used for cutting a foil strip, and the foil feeding unit is used for continuously providing the ultrasonic welding unit with a metal or nonmetal foil strip. The subtractive structure comprises a milling tool, and the control module is used for receiving a three-dimensional model of a part and controlling the additive structure and the subtractive structure. The foil feeding unit comprises a foil strip raw material wheel, a tensioning wheel, a limiting wheel, a conveying wheel and a conveying card, the tensioning wheel is internally provided with a tension sensor for monitoring the tension of the foil strip in real time and feeding back information to the interface of the control module, the limiting wheel is used for guiding the foil strip into the conveying wheel and limiting the outflow of the foil strip, the conveying wheel is used for controlling the feeding speed of the foil strip, the conveying wheel is driven to rotate by a motor, and the motor is controlled by the control module, the conveying card is used for accurately feeding the foil strip to the position below the ultrasonic welding unit, and the surface of the conveying wheel is provided with polyurethane limiting blocks.
2. The ultrasonic additive-subtractive integrated manufacturing apparatus according to claim 1, wherein, The workbench is internally provided with horizontally and vertically arranged heating wires.
3. The ultrasonic additive-subtractive integrated manufacturing apparatus according to claim 1, wherein, The ultrasonic welding unit comprises a connecting plate, an ultrasonic transducer, an ultrasonic amplitude transformer and an ultrasonic welding head, the connecting plate is connected with the main shaft, the ultrasonic transducer is located on the two sides of the ultrasonic amplitude transformer, and the ultrasonic welding head is located at the middle position of the ultrasonic amplitude transformer.
4. The ultrasonic additive-subtractive integrated manufacturing apparatus according to claim 3, wherein, The surface roughness of the ultrasonic welding head is Ra=25 mu m.