The Experimental and Theoretical Research of "Local Resonance" in Ultrasonic Honing System

In 1982, Professor Fang Guoliang found the "Non full resonance" phenomenon in a tool system while he use the thin-long tool ultrasonically machining deep-small hole. He called it as "local resonance". Also this "Non full resonance" phenomenon was discovered in the ultrasonic drilling and the ultrasonic honing system later. To its mechanism, professor Fang thought that the coupling of long-thin tool bar and driving system is weak, so the tool bar can vibrate independently, but the quantitative relation between the coupling factor and diameter ratio is not made certain. Then several theories come forth to interpret it but still haven’t a common conclusion. Through the systematic experimental and theoretical research, this paper reveals that the "local resonance" phenomenon of ultrasonic honing system has the same essence with the "local resonance" phenomenon in deep hole machining system: when the section area ratio of tool bar and driving system is small enough, some resonance frequencies of combined system are close to the resonance frequencies of "fixed-free" state tool bar, the combined system is still resonant. According to the given depth of hole and structure size, we can use the transfer matrix deduced in this paper to design flexible bar and oilstone seat not only satisfying mechanical structure size but also achieving enough magnitude. It greatly simplified the design. This new method can be named as "local resonance" design method for ultrasonic honing system. The experiment, deduction and design method have a certain common meaning to the study and design of other ultrasonic system.

Research on the New Technology and System of Ultrasonic Honing

In recent years, the new technology of ultrasonic vibration cutting has been drawing general attention. And great advancement in theory and applications in production of the technology have been achieved. Ultrasonic vibration honing system developed in North China Institute of Technology and Nanjing University of Aeronautics and Astronautics of cast iron cylinder (47×97) and thin cylinder of 20# (86×95) has been successfully applied to productive experiment and the technological effect obtained is ideal. In comparison with ordinary honing, ultrasonic vibration honing possesses apparent characteristics: Firstly, it has high processing precision (precision in size ranks IT6, roughness Ra0.05, circularty and cylindericity in size ranks IT6); Secondly, it has small cutting force and low temperature so that no deformation occurs; Thirdly, it has high efficiency. In this paper, the application of a new technique to honing is introduced, and the ultrasonic honing systems of thin cylinder and cast cylinder which have been successfully manufactured and their applying effect are illustrated. This paper analyzes the cutting principle of ultrasonic honing in terms of cutting motion, grain performance and cutting quantity. The study of this technique starts a new approach to which is efficient higher quality and lower consumption to hole’s precise and superprecise machining. At last,the paper introduce the conclution: Ultrasonic honing sharpens grain, which is favorable for raising cutting efficiency; Ultrasonic vibration honing may increase honing depth and raise cutting efficiency. It may also decrease honing power and system deformation; Undergoing practice we can find that the ultrasonic honing system as above discribed can be extended and applied to production. The system not only can be applied to conventional honing machine, its technology effect as good as high precision machine tool, but also can be applied to develop and study ultrasonic vibrating numbrical controlling honing machine tool which will provide a new type, efficient, high quality low consumption, equipment for working precision hole; Appling the same parament as W40 oilstone bar, under the same condition, is very valuable for product and application. Rough machining and finish machining once time finished, which not only improve location accuracy, but also have a high effiency.The honing system not only can be suitable for honing cast cylinder, but also can be applied for honing engineer ceramics as well as hard, crisp material; The dimension and technology paraments of 47 mm honing system as above discribed, can be suitable for honing the cast cylinder of motorcycle or minicar. And the cylinder diameter can be randomly selected from 45 to 65. The dimension and technology paramagnets of 86 honing system as above discribed,can be applied for honing all kinds of cylinder of light or heavy passenger-cargo vehicle, and the cylinder diameter can be randomly selected from 65 to 100; It is easy to achieve new technology of flat roof honing by applying ultrasonic honing.After the flat roof honing, fuel consumption of engine is 1g/Hp, while conventional engine is 3g/Hp.Life expectancy of engine is prolonged greatly after the cylinder by flat roof honing.

Non-Resonant Structure Design of Catenary Transformer in Ultrasonic Gear Honing

To solve the design problem of transformer composed of non-resonant structure in ultrasonic gear-honing, force coupling conditions for moderately thick annular plate （MTAP） and catenary horn are proposed, and the frequency equations of the transformer, which consist of an MTAP and a catenary horn, are derived based on Mindlin＇s theory. The design parameters of the transformer were obtained by solving the frequency equations with the help of MATLAB, and its mode and frequency were deduced by the modal analysis of finite element method （FEM）, which are consistent with the theoretical design demands. The transformer design can be extended from system with thin annular plate to that with MTAP as the theoretical method by the simulation analysis of various ratios of the thickness to radius.