To address the problem of the poor stability of ultrasonic machining of wave-absorbing honeycomb materials, this paper takes ultrasonic cutting of wave-absorbing honeycomb materials with a disc cutter as the research object and establishes a multi-degree-of-freedom mathematical model of the cutting system based on the relative positions of the tool and the honeycomb material and the motion characteristics of the tool. On this basis, modal analysis of the disc tool and the honeycomb cellular element wall plate is carried out to draw the Lobe diagram of ultrasonic cutting stability, the process experimental parameters are determined according to the solved stability Lobe diagram, and machining stability verification experiments are carried out. The experimental results show that the machining parameters in the stable region of the Lobe diagram result in a neat and clean surface, less fibre pullout, a complete outer substrate, and less tool wear than those in the critical and unstable regions, thus verifying the correctness of the theoretical model and the stability Lobe diagram.
To address the problem of the poor stability of ultrasonic machining of wave-absorbing honeycomb materials, this paper takes ultrasonic cutting of wave-absorbing honeycomb materials with a disc cutter as the research object and establishes a multi-degree-of-freedom mathematical model of the cutting system based on the relative positions of the tool and the honeycomb material and the motion characteristics of the tool. On this basis, modal analysis of the disc tool and the honeycomb cellular element wall plate is carried out to draw the Lobe diagram of ultrasonic cutting stability, the process experimental parameters are determined according to the solved stability Lobe diagram, and machining stability verification experiments are carried out. The experimental results show that the machining parameters in the stable region of the Lobe diagram result in a neat and clean surface, less fibre pullout, a complete outer substrate, and less tool wear than those in the critical and unstable regions, thus verifying the correctness of the theoretical model and the stability Lobe diagram.
To solve the problem of low processing efficiency of screw helical raceway by using high-efficiency grinding technology, this paper carried out theoretical, simulation and experimental analysis on the grinding temperature which mainly affects the selection of high-efficiency grinding process parameters. First, based on the distribution characteristics of the grinding allowance of the screw helical raceway, the analysis shows that the geometry of the grinding contact area is trapezoidal. Then, based on the existing triangular heat flux distribution model of the rectangular contact area, two heat flux distribution models of the triangle and the concave triangle are proposed according to the characteristics of the trapezoidal contact area. Finally, the plane grinding experiment was carried out to correct the simulation parameters, and the modified simulation parameters were used to predict the grinding temperature of the screw raceway, so as to achieve the maximum removal efficiency and avoid burns. The analysis results show that the highest temperature in the grinding area is on the lowest point of the helical raceway, and the temperature and temperature gradient in the grinding area obtained by using the concave triangular heat flux distribution model are the highest. By comparing the process parameters for the onset of grinding burns predicted by simulation and experimentally, the temperature predicted by the concave triangle heat flux distribution model in the trapezoidal contact area is higher than the actual temperature, while the temperature predicted by the triangle heat flux distribution model in the trapezoidal contact area is lower than the actual temperature.
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