硬质合金加工用无线超声刀柄开发

Developing of A Wireless Ultrasonic Tool Holder for Cemented Carbide Machining

钨钴硬质合金在加工过程中存在边缘崩缺、裂纹及表面质量低的现象,针对该问题,开发了一种适用于BT40锥柄的超声振子。使用ANSYS验证其振动模态和频率后与无线能量传输模块及锥柄进行装配,得到可适配普通BT40机床的无线超声刀柄;在无线刀柄上安装三种典型的硬质合金加工刀具,利用激光位移传感器标定不同激励电流下的工作频率及振幅。对YG6X硬质合金工件进行非球面的铣磨加工试验,结果显示超声铣磨可以有效降低普通铣磨过程中主轴转速较低时出现的工件边缘破损情况;增加主轴转速对于非球面底部的形状精度提高有限,但是增加超声振幅可以降低形状误差并降低底面轮廓线的粗糙度。

To solve the problems if edge-chipping,crack and poor surface quality in the machining process of tungsten carbide,an ultrasonic vibrator suitable for BT40 taper shank is developed.After verifying its vibration modal and frequency with ANSYS software,it was assembled with a wireless power transmission module and taper shank to obtain a wireless ultrasonic tool holder suitable for ordinary BT40 machine tools.Three typical tools for tungsten carbide machining were assembled on the wireless tool holder to calibrate the working frequency and vibration amplitude under different excitation currents using laser displacement sensor.The mill-grinding test of aspheric surface on YG6X cemented carbide workpiece was carried out.The results show that ultrasonic mill-grinding can effectively reduce the edge-chipping of the workpiece when the spindle speed is low in the ordinary mill-grinding process.Increasing the spindle speed has a limited effect on the form accuracy of the bottom of the mold,but increasing the ultrasonic amplitude can reduce the form error and the roughness of the bottom contour.