High-speed precision interrupted ultrasonic vibration cutting method

Patent metadata

Field	Value
Publication number	US-10118232-B2
Application number	US-201615297095-A
Country	US
Kind code	B2
Filing date	Oct 18, 2016
Priority date	Jun 21, 2016
Publication date	Nov 6, 2018
Grant date	Nov 6, 2018

Abstract

A high-speed precision interrupted ultrasonic vibration cutting method includes steps of: (1) installing an ultrasonic vibration apparatus on a machine tool, and stimulating a cutting tool to generate a transverse vibration, so as to realize varieties of machining processes; (2) realizing an interrupted cutting process by setting cutting parameters and vibration parameters to satisfy an interrupted cutting conditions; and (3) turning on the ultrasonic vibration apparatus and the machine tool, and starting a high-speed precision interrupted ultrasonic vibration cutting process. High-speed precision interrupted ultrasonic vibration cutting is able to be realized through the above steps during machining of difficult-to-machine materials in aviation and aerospace fields. A cutting speed is enhanced significantly, and exceeds a critical cutting speed of a conventional ultrasonic vibration cutting method and an elliptical ultrasonic vibration cutting method and even a high speed range of a traditional cutting method.

First claim

What is claimed is:

1. A high-speed precision interrupted ultrasonic vibration cutting method, comprising steps of:
(1) installing an ultrasonic vibration apparatus on a machine tool, and stimulating a cutting tool to generate a transverse vibration or a vibration with a transverse component, wherein: through combining different vibration types and machining process types, varieties of machining processes are able to be realized;
(2) realizing an interrupt cutting processing by setting cutting parameters and vibration parameters to satisfy interrupted cutting conditions and periodically separating the cutting tool from a finished surface profile of a workpiece; and
(3) turning on the ultrasonic vibration apparatus and the machine tool, and starting a high-speed precision interrupted ultrasonic vibration cutting process; wherein:
high-speed interrupted ultrasonic vibration cutting is able to be realized through the above steps during machining of difficult-to-machine materials in aviation and aerospace fields; a cutting speed is enhanced significantly, which exceeds a critical cutting speed of a conventional ultrasonic vibration cutting method and an elliptical ultrasonic vibration cutting method and even a high speed range of a traditional cutting method; besides, beneficial effects of cutting force and cutting temperature reductions, tool life prolonging, machining cost save, and surface quality and machining accuracy improvements are all obtained at the same time;
the interrupted cutting condition in the step (2) refers to a formula as listed of:

{

Δ
≤

2
⁢

⁢
A

2
⁢

⁢

arcsin
⁡

(

Δ
/
2

⁢

⁢
A

)

≤
ϕ
≤

2
⁢
π

-

2
⁢

⁢

arcsin
⁡

(

Δ
/
2

⁢

⁢
A

)

,

wherein: Δ is a center line offset value of two adjacent feed tool paths, which is related to the cutting parameters of feedrate and depth of cut, and determined according to a specific machining process and vibration types; ϕ is a phase difference of the two adjacent feed tool paths, which is related to the vibration parameters of tool vibration frequency and workpiece or tool rotatory speed, and determined according to the specific machining process and the vibration types; and A is a tool vibration amplitude.

2. The high-speed precision interrupted ultrasonic vibration cutting method, as recited in claim 1 , wherein the ultrasonic vibration apparatus in the step (1) is an apparatus which is able to stimulate the cutting tool to generate a transverse steady ultrasonic vibration or a steady ultrasonic vibration with a transverse component by amplifying a vibration generated by a transducer stimulated by an ultrasonic generator through an horn.

3. The high-speed precision interrupted ultrasonic vibration cutting method, as recited in claim 1 , wherein the machine tool in the step (1) is one of lathes, milling machines, drilling machines, grinding machines and machine centers; and the cutting tool in the step (1) is one of turning tools, milling tools, grinding tools, drilling tools, reamers and countersinks.

4. The high-speed precision interrupted ultrasonic vibration cutting method, as recited in claim 1 , wherein the transverse vibration or the vibration with the transverse component in the step (1) is an ultrasonic vibration on any point of the cutting tool, and a vibration direction thereof is vertical to a cutting speed direction.

5. The high-speed precision interrupted ultrasonic vibration cutting method, as recited in claim 1 , wherein the cutting parameters in the step (2) comprise the depth of cut, the feedrate and the cutting speed; and the vibration parameters in the step (2) comprise a vibration amplitude and a vibration frequency.

6. The high-speed precision interrupted ultrasonic vibration cutting method, as recited in claim 1 , wherein the step of “setting cutting parameters and vibration parameters” in the step (2) has principles that: a relative small Δ and a 180 degree phase difference are optimal for an interrupted separation of best effection; Δ is a parameter to scale a transverse relation of two adjacent feed tool paths while ϕ is a parameter to scale a longitudinal relation of the two adjacent feed tool paths, and, Δ and ϕ affect an interrupted separation effect simultaneously; when a value of Δ exceeds double of a value of a vibration amplitude, due to an oversized transverse distance between the two adjacent feed tool paths, whatever a value of ϕ, no interrupted separation effect occurs during the whole cutting process; conversely, when the value of ϕ is given in an appropriate neighborhood of zero, because no cross point exists at the two adjacent feed tool paths, whatever the value of Δ, no interrupted separation effect occurs during the whole cutting process.

7. The high-speed precision interrupted ultrasonic vibration cutting method, as recited in claim 1 , wherein the finished surface profile in the step (2) is a combination curve of six ar

Assignees

• Univ Beihang

Inventors

• Zhang Deyuan
• Zhang Xiangyu
• Sui He
• Xin Wenlong
• Jiang Xinggang

Classifications

• B23C9/005

  milling heads · CPC title

• B23C2215/04

  Aircraft components · CPC title

• B24B1/04

  subjecting the grinding or polishing tools, the abrading or polishing medium or work to vibration, e.g. grinding with ultrasonic frequency (involving oscillating or vibrating containers B24B31/06; superfinishing surfaces on work, e.g. by means of abrading blocks reciprocating with high frequency, B24B35/00) · CPC title

• B23C2265/16

  Elliptical · CPC title

• B23C2220/44

  High speed milling · CPC title