Ultrasonic machining acoustics system with compound tool
                              KANG Kai1, ZHANG Yundian1, ZHAO Meng1, ZHANG Hao2, JIN Yikun2, CHENG Hao2
(1.School of Mechanical Engineering, Hangzhou Dianzi University, Hangzhou 310018, China;2.Zhejiang Machinery Industry Information Institute, Hangzhou 310009, China)

Abstract: Aiming at the traditional processing of hard and brittle materials and composite materials which can produce many problems such as high processing difficulty,low processing efficiency and the poor quality, the acoustic system of rotary ultrasonic machining with composite tools used in machining hard and brittle materials and composite materials by rotating ultrasonic machining technology as well as the working mechanism of rotary ultrasonic machining was studied.The Pro/E Software was used to design for new rotating ultrasonic machining acoustics system.The sandwich type piezoelectric transducer was selected,which according to four terminal network method, the amplification coefficient equation and the frequency equation to design a new type of composite horn with 1/4 wave length.And a new type of electroplated diamond composite cutter was designed based on the equivalent mass method. The ANSYS Workbench software was used to analyze the new composite horn and the new compound tool, and the optimal solution of the model was obtained.The ultrasonic processing of the acoustic system was verified by hard and brittle material experiments.The result shows that the amplitude of amplitudevarying rod and cutting tool reach the maximum at about 20kHz frequency, which is an ideal mode. The design of the acoustic system can meet the requirements of machining hard and brittle materials and composite materials.

Key words: rotary ultrasonic machining; composite horn; electroplated diamond tool; modal analysis