CN108052074B - High-speed separation ultrasonic vibration cutting control method - Google Patents

High-speed separation ultrasonic vibration cutting control method Download PDF

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CN108052074B
CN108052074B CN201711348240.0A CN201711348240A CN108052074B CN 108052074 B CN108052074 B CN 108052074B CN 201711348240 A CN201711348240 A CN 201711348240A CN 108052074 B CN108052074 B CN 108052074B
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CN108052074A (en
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姜兴刚
马勇利
张德远
张翔宇
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Beihang University
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    • G—PHYSICS
    • G05—CONTROLLING; REGULATING
    • G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
    • G05B19/00—Programme-control systems
    • G05B19/02—Programme-control systems electric
    • G05B19/18—Numerical control [NC], i.e. automatically operating machines, in particular machine tools, e.g. in a manufacturing environment, so as to execute positioning, movement or co-ordinated operations by means of programme data in numerical form
    • G05B19/19—Numerical control [NC], i.e. automatically operating machines, in particular machine tools, e.g. in a manufacturing environment, so as to execute positioning, movement or co-ordinated operations by means of programme data in numerical form characterised by positioning or contouring control systems, e.g. to control position from one programmed point to another or to control movement along a programmed continuous path
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23Q—DETAILS, COMPONENTS, OR ACCESSORIES FOR MACHINE TOOLS, e.g. ARRANGEMENTS FOR COPYING OR CONTROLLING; MACHINE TOOLS IN GENERAL CHARACTERISED BY THE CONSTRUCTION OF PARTICULAR DETAILS OR COMPONENTS; COMBINATIONS OR ASSOCIATIONS OF METAL-WORKING MACHINES, NOT DIRECTED TO A PARTICULAR RESULT
    • B23Q15/00—Automatic control or regulation of feed movement, cutting velocity or position of tool or work
    • G—PHYSICS
    • G05—CONTROLLING; REGULATING
    • G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
    • G05B2219/00—Program-control systems
    • G05B2219/30—Nc systems
    • G05B2219/36—Nc in input of data, input key till input tape
    • G05B2219/36086—Select, modify machining, cutting conditions

Abstract

The invention relates to a high-speed separation ultrasonic vibration cutting control method. The invention provides a high-speed separation ultrasonic vibration cutting control method, which adopts an ultrasonic vibration cutting device comprising a closed-loop DDS (direct digital synthesizer), controls a cutter to vibrate in a direction vertical to the cutting speed in the cutting process, and simultaneously leads pits generated by transverse vibration in the motion tracks of two adjacent rotary cutters to be staggered and overlapped by controlling the phase difference of the motion tracks of the two adjacent rotary cutters in the cutting direction, thereby reducing the surface roughness deterioration degree caused by the vibration in the direction vertical to the cutting speed. Since the ultrasonic vibration includes a component perpendicular to the cutting speed direction, the magnitude of the cutting speed is not limited by the ultrasonic vibration cutting separation condition, and the ultrasonic vibration cutting can be performed at a high speed. By controlling the phase difference, the requirements of high-speed cutting and surface roughness can be met simultaneously.

Description

High-speed separation ultrasonic vibration cutting control method
Technical Field
The invention relates to a high-speed separation ultrasonic vibration cutting control method.
Background
Referring to fig. 1, in the conventional ultrasonic vibration cutting, ultrasonic vibration is applied to a tool in a cutting speed direction, which is called ultrasonic longitudinal vibration, and a tool movement trace is also shown in fig. 1. The ultrasonic vibration cutting realizes the periodic separation of the cutting edge of the cutter and the cutting chip of the workpiece, thereby reducing the cutting force, improving the quality of the processed surface and prolonging the service life of the cutter, and therefore, the ultrasonic vibration cutting is widely applied to the cutting processing of difficult-to-process materials. However, in the conventional ultrasonic vibration cutting process, in order to maintain such a periodic separation effect, there is a critical cutting speed vcThe critical cutting speed vcThe following formula is satisfied:
vc＝2πF·A
wherein v iscFor the cutting speed, F is the tool vibration frequency and A is the amplitude. If the cutting speed is higher than the critical cutting speed vcThe cutting edge of the tool can always contact with the chips, and the advantage of periodic separation of ultrasonic vibration is lost. Therefore, in practical applications, the cutting speed is generally not more than one third of the critical cutting speed, which results in that the conventional ultrasonic vibration cutting cannot be applied to the high-speed machining field.
Referring to fig. 2, if the vibration direction of the tool is perpendicular to the cutting speed direction, it is called ultrasonic transverse vibration, and meanwhile, the motion track of the tool is also shown in fig. 2. In this case, the cutting speed is not limited by the vibration frequency of the tool, and the ultrasonic vibration can be accelerated. However, this machining method is affected by ultrasonic vibration and spindle runout, and the machined surface is roughened, which is not satisfactory for surface roughness.
In conclusion, the existing ultrasonic vibration cutting technology cannot simultaneously meet the requirements of high-speed cutting and surface roughness.
Disclosure of Invention
Technical problem to be solved
The invention aims to provide a high-speed separation ultrasonic vibration cutting control method which can simultaneously meet the requirements of high-speed cutting and surface roughness.
(II) technical scheme
In order to achieve the purpose, the invention adopts the main technical scheme that:
the invention provides a high-speed separation ultrasonic vibration cutting control method, which adopts an ultrasonic vibration cutting device containing a closed-loop DDS (direct digital synthesizer), controls a cutter to vibrate in a direction vertical to a cutting speed in a cutting process, and simultaneously leads pits generated by vibration in the direction vertical to the cutting speed in the motion tracks of two adjacent rotary cutters to be staggered and overlapped by controlling the phase difference of the motion tracks of the two adjacent rotary cutters in the cutting direction.
According to the invention, the ultrasonic vibration cutting device comprises an ultrasonic vibration system, a rotary encoder, a spindle and a cutter, wherein the ultrasonic vibration system comprises an ultrasonic signal generator, a power amplifier and an ultrasonic transducer, the rotary encoder measures the current rotation frequency of the spindle in real time, an output signal of the rotary encoder is used as a reference clock signal of the ultrasonic signal generator, the output signal of the ultrasonic signal generator is amplified by the power amplifier and then sent to the ultrasonic transducer, the ultrasonic transducer converts an input electric signal into mechanical vibration, the cutter is excited to generate transverse ultrasonic vibration vertical to the cutting direction, and the ultrasonic signal generator is a DDS.
According to the present invention, the phase difference is controlled by controlling the ratio of the vibration frequency of the ultrasonic transducer and the rotation frequency of the spindle.
According to the invention, the vibration frequency and amplitude of the ultrasonic transducer and the spindle rotation frequency are determined according to some or all of the following equations:
Figure BDA0001509715860000021
wherein M is the ratio of the vibration frequency of the ultrasonic transducer to the rotation frequency of the main shaft, F is the vibration frequency of the ultrasonic transducer, and F is the vibration frequency of the ultrasonic transducerzIs the spindle rotation frequency, C is an integer value, and R is a decimal value;
θ＝2π×R
wherein, theta is phase difference and is expressed by a radian system, and R is a decimal value;
ap＜A
wherein, apFor depth of cut, A is the amplitude of the ultrasonic transducer;
v＝πDFz×60
wherein v is the cutting linear velocity, D is the workpiece diameter, FzIs the spindle rotation frequency.
According to the present invention, the vibration frequency of the ultrasonic transducer is set to the resonance frequency of the ultrasonic transducer.
According to the present invention, the vibration frequency of the ultrasonic transducer is controlled by controlling the frequency control word of the ultrasonic signal generator, the frequency control word is obtained by using the following formula according to the selected vibration frequency of the ultrasonic transducer, the word length of the frequency control word, the number of lines of the rotary encoder, and the selected spindle rotation frequency:
Figure BDA0001509715860000031
wherein X is a frequency control word, X ∈ (1, 2)K-1-1), F is the vibration frequency of the selected ultrasonic transducer, Fz is the spindle rotation frequency, K is the word length of the frequency control word, and p is the number of lines of the rotary encoder.
According to the invention, the rotary encoder obtains the output signal according to the number of lines of the rotary encoder and the current rotation frequency of the spindle, using the following formula:
fc＝p×Fz′
wherein f iscFor the output signal, p is the number of lines of the rotary encoder, Fz' is the current rotational frequency of the spindle.
According to the invention, the output frequency of the ultrasonic signal generator is obtained according to the output signal, the word length of the frequency control word and the frequency control word by adopting the following formula:
Figure BDA0001509715860000032
wherein, FsIs the output frequency, f, of the ultrasonic signal generatorcTo output a signal, X is a frequency control word and K is the word length of the frequency control word.
According to the invention, the tool is vibrated perpendicular to the direction of the cutting speed during the cutting process.
According to the invention, the stable phase difference control is combined with the stable feed amount control (the feed amount stable control adopts the existing mode), so that the pits of the motion tracks of two adjacent rotary cutters can be ensured to be regularly staggered and overlapped, further the pits formed on the surface of a workpiece are ensured to be regularly arranged, and the residual height of the pits is reduced:
Figure BDA0001509715860000041
h is the residual height of the pit, A is the amplitude of the ultrasonic transducer, theta is the phase difference, and theta is expressed by a radian system;
(III) advantageous effects
The invention has the beneficial effects that:
according to the high-speed separation ultrasonic vibration cutting control method, the phase difference of the motion tracks of the two adjacent rotary cutters along the cutting direction is controlled, so that pits generated by vibration perpendicular to the cutting speed direction in the motion tracks of the two adjacent rotary cutters are overlapped in a staggered mode, the cutter can cut off a blank cut part caused by separation of the cutter and the surface of a workpiece when the cutter rotates relative to the workpiece in the previous circle in the process of relative rotation of the cutter and the workpiece in the next circle, and the like, so that the surface roughness deterioration degree of the workpiece caused by vibration perpendicular to the cutting speed direction is reduced. Meanwhile, the ultrasonic vibration cutting device containing the closed-loop DDS is adopted to control cutting of the cutter, once the phase difference is determined, the phase difference is not changed by 'disturbance' of the main shaft in the working process, and therefore stable control of the phase difference is guaranteed. In conclusion, by controlling the phase difference and ensuring the stability of the determined phase difference in the actual machining process, the requirements of high-speed cutting and surface roughness can be met at the same time.
Drawings
Fig. 1 is a schematic view of a conventional ultrasonic longitudinal vibration cutting.
Fig. 2 is a schematic view of ultrasonic transverse vibration cutting.
Fig. 3 is a schematic diagram of pit dislocation overlap caused by transverse vibration in the motion trajectories of two adjacent rotary tools in the cutting direction in the high-speed separation ultrasonic vibration cutting control method according to the following embodiment, which is shown from a view point showing the motion trajectories of the tools in a direction parallel to the surface of a workpiece.
Fig. 4 is another schematic diagram of pit dislocation overlapping caused by transverse vibration in the motion trajectories of two adjacent rotary cutters in the cutting direction in the high-speed separation ultrasonic vibration cutting control method according to the following specific embodiment, which is shown from a top view along the transverse vibration direction.
Fig. 5 is a schematic working diagram of the ultrasonic vibration cutting phase difference control method in the cutting process according to the following embodiment.
FIG. 6 is a schematic diagram of a high-speed separation ultrasonic vibration cutting control method applied to turning according to the following embodiments;
FIG. 7 is a graph of the effect of the smooth texture of the machined surface using the high speed discrete ultrasonic vibration cutting control method provided in the following embodiments;
fig. 8 is a close-up view of the machined surface texture of fig. 7.
[ reference numerals ]
1: a workpiece; 2: and (4) a cutter.
Detailed Description
For the purpose of better explaining the present invention and to facilitate understanding, the present invention will be described in detail by way of specific embodiments with reference to the accompanying drawings.
Referring to fig. 3 to 8, in the present embodiment, a high-speed separation ultrasonic vibration cutting control method is provided, in which an ultrasonic vibration cutting apparatus including a closed-loop DDS is used, and the vibration direction of the tool 2 is controlled to be perpendicular to the cutting speed direction or to have a component perpendicular to the cutting speed direction, that is, the tool 2 is controlled to make vibration including vibration perpendicular to the cutting speed direction during cutting (including both cases of lateral vibration only and a component having lateral vibration). When the condition a is satisfiedp(depth of cut)<And when the vibration amplitude is A, the cutter and the workpiece can be periodically separated in the ultrasonic vibration process, and the cutting speed is irrelevant. But the transverse vibrations will cause the tool 2 to pit the surface of the workpiece 1. The motion tracks of two adjacent rotary cutters (such as y in figure 3) are controlled by controlling the phase difference of the motion tracks of two adjacent rotary cutters along the cutting direction0And y1Corresponding two tool motion trajectories) are overlapped by the pit displacement caused by the transverse vibration. Wherein the above-mentioned "two adjacent revolutions" means that the workpiece 1 and the tool 2 rotate relatively over two revolutions, for example, in the case of a rotation of the workpiece 1 as in turning, the above-mentioned "two adjacent revolutions" means that the workpiece 1 rotates over two revolutions, and in the case of a rotation of the tool 2 as in milling, the above-mentioned "two adjacent revolutions" means that the tool 2 rotates over two revolutions.
Therefore, through controlling the phase difference of the motion tracks of the two adjacent rotary cutters along the cutting direction, pits generated by transverse vibration in the motion tracks of the two adjacent rotary cutters are overlapped in a staggered mode, and further in the relative rotation process of the cutter 2 and the workpiece 1 in the next circle, the cutter 2 can cut off the blank cutting part caused by transverse vibration separation in the relative rotation process of the previous circle, and the like, so that the residual height of the pits of the workpiece 1 is reduced, and the surface roughness deterioration degree caused by the transverse vibration is reduced. Meanwhile, the ultrasonic vibration cutting device containing the closed-loop DDS is adopted to control cutting of the cutter, once the phase difference is determined, the phase difference is not changed by 'disturbance' of the main shaft in the working process, and therefore stable control of the phase difference is guaranteed. Therefore, in summary, by controlling the above-described phase difference and by ensuring the stability in the actual machining process after the phase difference is determined, the requirements of high-speed cutting and surface roughness can be satisfied at the same time.
Further, in the present embodiment, taking turning as an example, referring to fig. 5, the high-speed split ultrasonic vibration cutting control method is applied to an ultrasonic vibration cutting apparatus (e.g., a machine tool) including an ultrasonic vibration system, a rotary encoder, a spindle, and a tool 2. The ultrasonic vibration system comprises an ultrasonic signal generator, a power amplifier and an ultrasonic transducer. A cutter 2 is arranged on a feeding tool rest of a machine tool, and a workpiece 1 is a rotary body and is arranged on a main shaft through a three-grab chuck to rotate at a high speed. The rotary encoder is arranged at the tail end of the main shaft, rotates at a high speed together with the main shaft and is used for measuring the current rotating frequency of the main shaft in real time. The output signal of the rotary encoder is used as a reference clock signal of an ultrasonic signal generator, the output signal of the ultrasonic signal generator is sent to an ultrasonic transducer through a power amplifier, the ultrasonic transducer converts the input electric signal into mechanical vibration (namely ultrasonic wave), and the cutter 2 is excited to generate transverse ultrasonic vibration vertical to the cutting direction, and the frequency (F) of the vibration is equal to the output frequency (F) of the ultrasonic signal generators). In the present embodiment, the ultrasonic signal generator is a Direct Digital Synthesizer (DDS), and the material of the workpiece 1 is Ti-6 Al-4V. Further, in the present embodiment, the phase difference is controlled by controlling the ratio of the vibration frequency of the ultrasonic transducer and the spindle rotation frequency. Specifically, the vibration frequency and amplitude of the ultrasonic transducer and the spindle rotation frequency are determined by the following steps:
s1, obtaining a decimal value in the ratio of the selected vibration frequency of the ultrasonic transducer and the selected rotation frequency of the main shaft by adopting the following formula:
Figure BDA0001509715860000061
wherein F is the vibration frequency of the ultrasonic transducer, FzIs the spindle rotation frequency, C is an integer value, R is a decimal numberValues, F and FzThe same unit, Hz is preferred in this embodiment. The vibration frequency of the ultrasonic transducer is preferably the resonance frequency of the ultrasonic transducer, or a value located near the resonance frequency. The main shaft rotation frequency is within a certain range according to the actual working condition requirement.
S2, obtaining the phase difference according to the decimal value by adopting the following formula:
θ＝2π×R
wherein, theta is phase difference and is expressed by a radian system, and R is a decimal value.
S3, determining the amplitude of the ultrasonic transducer according to the cutting depth by adopting the following formula:
ap<A
wherein, apFor depth of cut, A is the amplitude of the ultrasonic transducer, apThe unit is the same as A, and is preferably μm in this embodiment.
In summary, it can be understood that the phase difference can be controlled to a desired value by controlling the vibration frequency and amplitude of the ultrasonic transducer and the spindle rotation frequency to the calculated values. Of course, in actual practice, the above values may be selected through repeated checking, correction and refinement. In this embodiment, through repeated checking and perfecting, the following is finally selected: f is 20804Hz, Fz＝30Hz，C＝693，R＝0.47，θ＝0.94π，ap7 μm, 10 μm for a in the range of 6-15 μm.
It can also be seen that the amplitude of the ultrasonic transducer cannot be selected too low, which would result in a depth of cut that is too low to significantly affect the machining efficiency. In this embodiment, ap7 μm. The depth of cut was calculated before machining and was not changed during machining.
Further, in the present embodiment, the vibration frequency of the ultrasonic transducer is controlled by controlling a frequency control word of the ultrasonic signal generator, the frequency control word is obtained from the selected vibration frequency of the ultrasonic transducer, the word length of the frequency control word, the number of lines of the rotary encoder, and the spindle rotation frequency by using the following formula:
Figure BDA0001509715860000071
wherein X is a frequency control word, X ∈ (1, 2)K-1-1), F is the vibration frequency of the ultrasonic transducer, the vibration frequency of the ultrasonic transducer selected in the previous step is substituted in calculation, K is the word length of the frequency control word, p is the number of lines of the rotary encoder, FzSubstituting the calculated spindle rotation frequency into the spindle rotation frequency obtained in the previous step, wherein F and FzThe units of (a) are the same. In this embodiment, K is 20, p is 36000, and X is calculated to be 20198. The frequency control word is calculated before machining and is unchanged during machining.
Further, the cutting linear velocity is obtained from the diameter of the workpiece 1 and the spindle rotational frequency using the following formula:
v＝πDFz×60
wherein v is the cutting linear velocity, D is the workpiece diameter, FzAnd substituting the spindle rotation frequency obtained by calculation in the previous step during calculation. In this example, D is 0.08m, FzHigh speed cutting has been achieved at 30Hz, 3.14 × 0.08 × 30 × 60 452m/min, according to the formula vcThe maximum cutting speed of ultrasonic longitudinal vibration is only 78.4m/min 2 pi F · a.
The feed amount f is selected according to the shape of the tool 2 so that the dimples generated by the lateral vibration can overlap each other in the feed direction. In the present embodiment, the feed amount f is 0.05 mm/r.
In summary, before machining, the frequency control word, the spindle rotation frequency, the amplitude of the ultrasonic transducer, and the feed amount are determined, and then machining is performed according to the determined parameters. Thus, the phase difference can be controlled by setting the frequency control word and amplitude of the ultrasonic transducer and the spindle rotation frequency for each machining. Thus, in the present embodiment, the surface roughness is reduced from 0.785 in the phase difference-free control to 0.303, which is significantly reduced.
Further, referring to fig. 5, during the machining process, the current rotation frequency of the spindle is measured in real time by the rotary encoder, and the rotary encoder obtains an output signal as a reference clock signal of the ultrasonic signal generator according to the number of lines of the rotary encoder and the current rotation frequency of the spindle by using the following formula:
fc＝p×Fz′
wherein f iscFor the output signal, p is the number of lines of the rotary encoder, Fz' is the current rotational frequency of the spindle, fcAnd FzThe unit of' is the same, in this example all Hz.
And in the processing process, the output frequency of the ultrasonic signal generator adopts the following formula and is obtained according to the output signal, the word length of the frequency control word and the frequency control word:
Figure BDA0001509715860000091
wherein, FsIs the output frequency, f, of the ultrasonic signal generatorcFor the output signal, X is a frequency control word, K is the word length of the frequency control word, FsAnd fcThe same unit is used for all the embodiments in Hz.
In general, a reference clock signal of the DDS is usually generated by a crystal oscillator to generate a clock signal with a fixed frequency, and the output frequency of the DDS is fixed under the action of a certain frequency control word, which is called as an open-loop DDS. In the present embodiment, the reference clock signal of the DDS is generated by a rotary encoder, and when the spindle is "jumped" due to interference during rotation, the current rotation frequency F of the spindlez' occurrence is not equal to the spindle rotation frequency F set before machiningzIn the case of DDS, reference clock signal f of DDScAlso proportionally, such DDS is referred to as closed-loop DDS. The ratio of the ultrasonic vibration frequency of the tool 2 to the rotational frequency of the spindle is shown by the following equation:
Figure BDA0001509715860000092
when the main shaft generates 'jump' due to interference in the rotating process, FzWill change(ii) a At the same time, F follows FzProportionally, but the ratio M of the two does not change with the "run out" of the spindle. And because of adopting the closed-loop DDS technology, once the phase difference is determined, the phase difference is not changed by the disturbance of the main shaft in the working process. Therefore, the closed-loop DDS technology realizes the stable control of the phase difference, and as can be seen from fig. 7 and 8, the stable phase difference control combined with the stable feed amount control (the feed amount stable control adopts the existing mode) can ensure that pits of the motion tracks of two adjacent rotary cutters are regularly staggered and overlapped, further ensure that the pits formed on the surface of a workpiece are regularly arranged, and reduce the residual height of the pits:
Figure BDA0001509715860000093
wherein h is the residual height of the pit, a is the amplitude of the ultrasonic transducer, θ is the phase difference, and h and a have the same unit, preferably μm in the embodiment; theta is expressed in radians.
In summary, the high-speed separation ultrasonic vibration cutting control method in the embodiment has the following advantages:
firstly, the closed-loop DDS realizes the stability and controllability of the phase difference of two adjacent rotating micro pits along the cutting direction, so that the surface roughness level of transverse vibration processing is reduced by accurately controlling the phase difference, the cutting speed limit is broken through, and the separation can be still realized under the high-speed condition;
secondly, the high-speed separation ultrasonic vibration cutting control method can be applied to various cutting processing technologies, such as turning, milling, grinding, drilling and the like, so as to achieve the purpose of reducing the residual height of a processing pit of a difficult-to-process material under the condition of high-speed separation ultrasonic vibration processing;
thirdly, by reasonably setting cutting parameters (mainly the rotation frequency of the main shaft) and ultrasonic vibration parameters (mainly the vibration frequency and the vibration amplitude of the ultrasonic transducer), the phase difference control method can obtain stable and controllable microscopic surface texture.
Of course, the determination steps of the above parameter values are only one embodiment, and in other embodiments, adjustment may be performed as long as the requirements of high-speed cutting and surface roughness can be satisfied by controlling the phase difference of each machining, that is, by setting the phase difference. Preferably, the phase difference is controlled according to a part of or all of the following formulas, that is, the parameter values are determined comprehensively according to a part of or all of the following formulas, so as to realize the stable control of the high-speed separation ultrasonic vibration cutting phase difference:
θ＝2π×R
wherein, theta is phase difference and is expressed by a radian system, and R is a decimal value.
Figure BDA0001509715860000101
Wherein M is the ratio of the vibration frequency of the ultrasonic transducer to the rotation frequency of the main shaft, F is the vibration frequency of the ultrasonic transducer, and F is the vibration frequency of the ultrasonic transducerzIs the spindle rotation frequency, C is an integer value, R is a decimal value, F and FzThe units of (a) are the same.
ap＜A
apFor depth of cut, A is the amplitude of the ultrasonic transducer, apThe same units as A.
Figure BDA0001509715860000102
Wherein X is a frequency control word, X ∈ (1, 2)K-1-1), F is the vibration frequency of the ultrasonic transducer, K is the word length of the frequency control word, p is the number of lines of the rotary encoder, FzFor the spindle rotation frequency, F and FzThe units of (a) are the same.
v＝πDFz×60
Wherein v is the cutting linear velocity, D is the workpiece diameter, FzIs the spindle rotation frequency.
The above description is only a preferred embodiment of the present invention, and for those skilled in the art, the present invention should not be limited by the description of the present invention, which should be interpreted as a limitation.

Claims (6)

1. A high-speed separation ultrasonic vibration cutting control method is characterized in that,
the ultrasonic vibration cutting device comprising a closed-loop DDS is adopted to control the cutter to vibrate in a direction vertical to the cutting speed in the cutting process, and meanwhile, pits generated in the motion tracks of two adjacent rotary cutters due to the vibration in the direction vertical to the cutting speed are overlapped in a staggered mode by controlling the phase difference of the motion tracks of the two adjacent rotary cutters in the cutting direction, wherein the two adjacent rotations mean that a workpiece and the cutter rotate relatively for two circles;
the ultrasonic vibration cutting device comprises an ultrasonic vibration system, a rotary encoder, a spindle and a cutter, wherein the ultrasonic vibration system comprises an ultrasonic signal generator, a power amplifier and an ultrasonic transducer, the rotary encoder measures the current rotation frequency of the spindle in real time, an output signal of the rotary encoder serves as a reference clock signal of the ultrasonic signal generator, the output frequency of the ultrasonic signal generator is amplified by the power amplifier and then is sent to the ultrasonic transducer, the ultrasonic transducer converts an input electric signal into mechanical vibration and excites the cutter to generate transverse ultrasonic vibration perpendicular to the cutting direction, and the ultrasonic signal generator is a DDS;
the output frequency of the ultrasonic signal generator is obtained according to the output signal, the word length of the frequency control word and the frequency control word by adopting the following formula:
Figure FDA0002608326900000011
wherein, FsIs the output frequency, f, of the ultrasonic signal generatorcFor the output signal, X is the frequency control word, the frequency control word is calculated before processing, the frequency control word is not changed in the processing process, and K is the word length of the frequency control word;
and obtaining a decimal value in the ratio of the selected vibration frequency of the ultrasonic transducer to the selected rotation frequency of the main shaft by adopting the following formula:
Figure FDA0002608326900000012
wherein F is the vibration frequency of the ultrasonic transducer, FzIs the spindle rotation frequency, C is an integer value, R is a decimal value, F and FzThe units are the same;
the phase difference is obtained from the fractional values using the following formula:
θ＝2π×R
wherein, theta is phase difference and is expressed by a radian system, and R is a decimal value.
2. The high-speed separation ultrasonic vibration cutting control method according to claim 1, wherein the vibration frequency and amplitude of the ultrasonic transducer and the spindle rotation frequency are determined according to a part of or all of the following formulas:
Figure FDA0002608326900000021
θ＝2π×R；
ap＜A
wherein, apFor depth of cut, A is the amplitude of the ultrasonic transducer;
v＝πDFz×60
wherein v is the cutting linear velocity, D is the workpiece diameter, FzIs the spindle rotation frequency.
3. The high-speed separation ultrasonic vibration cutting control method according to claim 2,
the vibration frequency of the ultrasonic transducer is set to the resonance frequency of the ultrasonic transducer.
4. The high-speed separation ultrasonic vibration cutting control method according to claim 2,
controlling the vibration frequency of the ultrasonic transducer by controlling a frequency control word of the ultrasonic signal generator, wherein the frequency control word is obtained according to the selected vibration frequency of the ultrasonic transducer, the word length of the frequency control word, the number of lines of a rotary encoder and the selected rotation frequency of the spindle by adopting the following formula:
Figure FDA0002608326900000022
wherein X is the frequency control word, X ∈ (1, 2)K-1-1), F being the selected vibration frequency of the ultrasonic transducer, FzAnd K is the main shaft rotation frequency, K is the word length of the frequency control word, and p is the line number of the rotary encoder.
5. The high-speed separation ultrasonic vibration cutting control method according to claim 4,
the rotary encoder obtains the output signal according to the number of lines of the rotary encoder and the current rotation frequency of the spindle by adopting the following formula:
fc＝p×Fz′
wherein f iscFor the output signal, p is the number of lines of the rotary encoder, Fz' is the current rotational frequency of the spindle.
6. The high-speed separation ultrasonic vibration cutting control method according to any one of claims 1 to 5,
the tool vibrates in a direction perpendicular to the cutting speed during cutting.
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