CN114146889A - Dual excitation longitudinal-radial mode conversion high-power ultrasonic vibration system - Google Patents
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- B06B3/00—Methods or apparatus specially adapted for transmitting mechanical vibrations of infrasonic, sonic, or ultrasonic frequency
- B06B3/02—Methods or apparatus specially adapted for transmitting mechanical vibrations of infrasonic, sonic, or ultrasonic frequency involving a change of amplitude
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Abstract
The invention discloses a dual excitation longitudinal-radial mode conversion high-power ultrasonic vibration system, which comprises a disk-shaped tool head and two dual thick disk electrode ultrasonic transducers arranged on two sides of the disk-shaped tool head; the thick disc electrode ultrasonic transducer comprises a rear cover plate, a first piezoelectric wafer stack, a thick disc electrode, a second piezoelectric wafer stack and a front cover plate which are sequentially connected in series through a prestressed bolt, wherein the front cover plate is fixed with the axis of one side of the disc-shaped tool head through an amplitude transformer; the longitudinal vibration of two pairs of thick disc electrode ultrasonic transducers and amplitude transformers is converted into the radial vibration of the central disc-shaped tool head; the thick disk electrode is uniformly provided with radial through holes along the circumferential surface, and the thick disk electrode with proper thickness is selected to ensure that the effective electromechanical coupling coefficient of the transducer is higher. By utilizing the invention, larger output displacement amplitude can be obtained, more uniform radial vibration can be generated, and the precision and the efficiency of cutting and welding can be improved.
Description
Technical Field
The invention belongs to the technical field of ultrasonic transducer processing, and particularly relates to a dual excitation longitudinal-radial mode conversion high-power ultrasonic vibration system.
Background
The function of the ultrasonic transducer is to convert the input ultrasonic frequency electric energy into mechanical energy (ultrasonic wave) and transmit the mechanical energy (ultrasonic wave), and a small part of energy is consumed by the ultrasonic transducer. Ultrasonic waves have the excellent characteristics of high efficiency, energy conservation, environmental protection, and are widely applied to the fields of cutting, welding, material forming, machining and the like at present. Particularly, with the development of new materials and the need of efficient and precise manufacturing of aerospace high-performance components, the ultrasonic processing technology is gradually becoming one of the main development directions in the field of efficient and precise manufacturing as a new processing method.
Ultrasonic welding is that ultrasonic frequency electric energy provided by an ultrasonic power supply is converted into mechanical vibration with the same frequency through a transducer, displacement amplitude is amplified and transmitted to a welding tool head through an amplitude transformer, and the tool head performs strong ultrasonic vibration on the surface of a weldment under pressure. At this time, the two welded parts are subjected to high-frequency friction under vertical pressure, so that the rough surface is sheared and deformed, temperature rise and plastic flow are generated, the surface oxide film and the organic film are simultaneously removed and dispersed, a clean contact surface is generated, and finally the two surfaces are in close contact and connected. Ultrasonic welding is a solid state connection, and because the welding zone temperature is low, the materials cannot be melted, the structure of the materials is not changed, and the ultrasonic welding is particularly suitable for welding different materials. In the welding process, no material or welding flux is needed to be added, gas protection is not needed, only about 5% of energy of the traditional welding is consumed, and the method has the advantages of environmental protection and energy saving.
In the prior art, the utility model patent of the utility model discloses a grant bulletin No. CN 207900447U, the name is "rotation regulation subassembly, symmetry rotation regulation device and ultrasonic wave roll welding equipment", through the spring leaf with interconnect between roll welding bonding tool and the rotating member, when the bonding tool vibrates along its axial direction, the spring can effectively avoid driving the vibration of rotating member, improves welded precision and stability. However, the horn body is coupled to the transducer via the horn coupler, which results in energy transfer losses and reduced energy conversion efficiency.
Chinese patent publication No. CN 108393573 a discloses an ultrasonic rolling welding machine, in which a spindle system includes an ultrasonic welding head, an amplitude modulator, a motor and a transducer, and the motor and the transducer are respectively located at two sides of the welding head. The motor is used for driving the bearing system to realize the rotation of the welding head, so that the amplitude modulator on the motor side does not have the function of increasing the amplitude of the welding head, but consumes the energy of the vibration of the welding head.
Chinese patent publication No. CN 112776345 a discloses an ultrasonic rolling welding device with longitudinal-radial coupled vibration, in which an ultrasonic vibration part is formed by coaxially connecting an ultrasonic transducer, an amplitude transformer and a tool head through bolts, so as to solve the problem of conflict coordination among the ultrasonic isolation, the fixing mode and the rotating mode of a longitudinal-radial coupled vibration system.
The above-disclosed patent documents have common disadvantages:
(1) the transducer is disposed at only one end of the horn, resulting in limited welding power, and not achieving the high power and large amplitude sought for ultrasonic welding. (2) The single-sided transducer excited horn produces non-uniform longitudinal-radial coupled vibration, i.e., non-uniform edge-to-center amplitude, resulting in non-uniform welding energy output. (3) The horn is shaped as a plain disc, which is not optimized and does not have the maximum amplitude magnification. (4) The welding head has a single structure and cannot meet more welding requirements.
Chinese patent publication No. CN 112810162 a discloses a double-roller ultrasonic rolling welding device with longitudinal-radial coupled vibration, in which the double-roller rolling welding tool head is composed of two butt-jointed T-shaped rolling welding tool heads, the end disc structures of the two are connected by bolts to realize symmetrical arrangement, and the end parts of the axial amplitude transformer are respectively connected with an ultrasonic transducer. On the basis of the invention patent (publication No. CN 112776345A, named as 'an ultrasonic rolling welding device with coupled vibration in longitudinal and radial directions'), the end disc structures of the two parts are mechanically and symmetrically distributed in series through bolts. However, each tool head is still excited only by the corresponding ultrasonic transducer and performs reverse vibration, and the effects of power synthesis and amplitude increase of the two end transducers are not achieved.
Ultrasonic cutting is a novel process technology which utilizes an ultrasonic power supply to drive cutting equipment to vibrate at ultrasonic frequency, and transmits collision and impact energy to a cut medium through a cutter head, so that the material of the cut medium is fatigue-broken to achieve a cutting effect. The introduction of ultrasonic vibration can obviously reduce cutting force, reduce cutter abrasion, reduce microcracks, reduce surface roughness, improve surface processing quality, reduce dust pollution and the like. Ultrasonic cutting can more effectively and accurately process composite materials and hard and brittle materials, such as optical glass, silicon crystals, ceramics and the like, used in the aerospace manufacturing field, such as carbon fibers, glass fibers, Kevlar fibers, various honeycomb materials and the like.
In the prior art, the invention patent of the publication No. CN 108582260B, which is named as an ultrasonic cutting device for reclaimed rubber, realizes the cutting of reclaimed rubber wound on a winding drum by driving an outer sliding sleeve provided with an ultrasonic cutter to move left and right along an air cylinder through a permanent magnet piston. The ultrasonic cutter for cutting comprises an energy converter, an amplitude transformer and a cutter, wherein the energy converter amplifies the longitudinal vibration of ultrasonic frequency through the amplitude transformer and then transmits the amplified longitudinal vibration to the cutter. However, the transducer is installed in the winding drum, and heat generated in the working process is not easy to conduct out, so that the problem that the electromechanical conversion efficiency of the transducer is sharply reduced due to the temperature rise is caused.
Chinese patent publication No. CN 109434268A discloses an ultrasonic cutting and welding composite mechanism, which binds tool knives for welding and cutting into an integral structure, so as to achieve the effect of synchronously welding and cutting materials. The ultrasonic cutting head and the welding head are respectively arranged on the lower end surface of the female tool head, but only part of longitudinal vibration energy of the female tool head is transmitted to the cutting head and the welding head, so that the conversion efficiency of the vibration energy is reduced.
Chinese patent publication No. CN 108436187 a discloses an ultrasonic cutting and impact integrated processing method for aluminum honeycomb, in which longitudinal vibration generated by an ultrasonic vibration system is converted into bending vibration of a circular blade, a main shaft of a machine tool drives the blade to rotate, and the aluminum honeycomb to be processed is processed according to a feed path. Because the longitudinal section of the circular blade knife is isosceles trapezoid, the bending vibration generated by the blade is uneven, and a vibration pitch line circle exists, namely the amplitude difference of the lower end surface of the blade is larger. The tool axis is always perpendicular to the feed path, so the bending vibration direction of the circular blade is not the same as the feed path, thereby reducing cutting efficiency and accuracy.
The ultrasonic vibration systems of the above patent documents are each a single longitudinal vibration ultrasonic transducer, and it is difficult to achieve a large power and a large amplitude required for ultrasonic cutting, thereby limiting the range of cutting materials.
Chinese patent publication No. CN 108340023 a discloses an ultrasonic vibration system for cutting honeycomb core material, which includes two-stage vibration systems, each of which consists of a transducer and a horn. Although the coupling of the two-stage vibration system increases the power and the amplitude, the vibration at the center of the first-stage amplitude transformer is not coupled to the second-stage vibration system, so that the loss of vibration energy is caused; the back cover plate and the piezoelectric ceramic crystal stack of the secondary vibration system are positioned in the amplitude transformer of the primary vibration system, and the closed space is not beneficial to the heat dissipation of the secondary ultrasonic system, so that the vibration performance of the transducer is changed due to overhigh temperature of the piezoelectric ceramic crystal stack.
Disclosure of Invention
Based on the defects in the prior art, the invention provides a dual excitation longitudinal-radial mode conversion high-power ultrasonic vibration system, which can obtain larger output displacement amplitude and generate uniform radial vibration compared with the conventional ultrasonic rolling welding and cutting transducer, thereby improving the precision and efficiency of cutting and welding.
A dual excitation longitudinal-diameter mode conversion high-power ultrasonic vibration system comprises a disc-shaped tool head and two dual thick disc electrode ultrasonic transducers arranged on two sides of the disc-shaped tool head;
the thick disc electrode ultrasonic transducer comprises a rear cover plate, a first piezoelectric wafer stack, a thick disc electrode, a second piezoelectric wafer stack and a front cover plate which are sequentially and tightly connected in series through a prestressed bolt, wherein the front cover plate is fixed with the axis of one side of the disc-shaped tool head through an amplitude transformer; the longitudinal vibration of two pairs of thick disc electrode ultrasonic transducers and amplitude transformers is converted into the radial vibration of the central disc-shaped tool head; the thick disk electrode is uniformly provided with radial through holes along the circumferential surface.
To ensure a high effective electromechanical coupling coefficient of the transducer, a thick disk electrode of suitable thickness is selected.
In the invention, the thick disk electrode is provided with radial through holes which are uniformly distributed along the circumference, so that the heat dissipation and cooling of the piezoelectric wafer stack can be accelerated, and larger output displacement amplitude can be obtained; the dual excitation center disc-shaped tool head generates uniform radial vibration, so that the precision and the efficiency of cutting and welding are improved; impact force on the radial surface of the disc-shaped tool head in the working process cannot directly act on the transducer, and the risk that the transducer is damaged is greatly reduced.
Furthermore, the thick disc electrode is a negative electrode and is arranged at the vibration displacement nodal plane of the thick disc electrode ultrasonic transducer. And by combining the radial through holes on the thick disk electrode, the equivalent elastic constant near the displacement nodal plane of the transducer is reduced, and larger output displacement amplitude can be obtained.
Further, the first piezoelectric wafer stack and the second piezoelectric wafer stack both comprise an even number of piezoelectric wafers.
Furthermore, a flange plate is arranged outside the thick disc electrode ultrasonic transducer at the vibration displacement joint surface; the flange plate and the thick disc electrode ultrasonic transducer are of an integrated structure or a split structure, and when the split structure is adopted, the flange plate and the thick disc electrode ultrasonic transducer are in interference fit.
Further, the front cover plate and the amplitude transformer are of an integrated structure, or the front cover plate and the amplitude transformer are tightly connected through bolts.
Furthermore, the amplitude transformer adopts a primary amplitude transformer or a multi-stage amplitude transformer cascade system; the amplitude transformer is in a step shape, a conical shape, an exponential shape or a Gaussian shape.
Further, the amplitude transformer and the disc-shaped tool head are of an integrated structure, or the amplitude transformer and the disc-shaped tool head are tightly connected through bolts.
Furthermore, the disc-shaped tool heads are respectively a disc-shaped welding tool head and a disc-shaped cutting tool head; the outer end face of the disc-shaped welding tool head is provided with fine patterns such as grid patterns, cross patterns, centripetal patterns and the like, so that the surface of the obtained welding material has different micro-appearances. The outer end face of the disc-shaped cutting tool head has a cutting edge angle.
The structure of disc-shaped tool head is various, the application range of ultrasonic rolling welding and cutting is enlarged, and the disc-shaped welding tool head or the disc-shaped cutting tool head can be replaced according to application requirements.
Further, the cross-sectional shape of the disc-shaped tool head is a power function, an exponent, a broken line or a cosine curve.
Compared with the prior art, the invention has the following beneficial effects:
1. the dual excitation longitudinal-radial mode conversion high-power ultrasonic vibration system provided by the invention converts the longitudinal vibration of the two dual ultrasonic transducers and the amplitude transformer into the radial vibration of the middle disc-shaped tool head, and realizes the high power and large amplitude pursued by the conventional ultrasonic welding and cutting.
2. The two dual transducers are thick disc electrode ultrasonic transducers, the thick disc electrodes can accelerate the heat dissipation and cooling of the piezoelectric crystal stack, and the working thermal stability and the electromechanical conversion efficiency of the piezoelectric transducers are improved.
3. The thick disk electrode of the invention is provided with radial through holes which are uniformly distributed along the circumference and are arranged at the vibration displacement nodal plane position of the transducer, and the through holes reduce the equivalent elastic constant near the vibration displacement nodal plane of the transducer, thereby obtaining larger output displacement amplitude.
4. The invention takes the disc-shaped tool head as the center, and the amplitude transformer and the transducer at the two ends are symmetrically distributed, so that the longitudinal vibration generated at the two ends is converted into the radial vibration of the disc-shaped tool head uniformly, thereby improving the precision and the efficiency of cutting and welding.
5. The disc-shaped tool head of the invention is impacted greatly in the radial direction in the working process, but the direction of the impact force is vertical to the longitudinal vibration direction of the transducer, so that the impact force can not directly act on the transducer, and the risk of damaging the transducer is greatly reduced.
6. The disc-shaped tool head has various structures, and tool heads with different shapes are selected according to the characteristics and the size of materials, so that the application range of ultrasonic rolling welding and cutting is expanded.
Drawings
FIG. 1 is a schematic diagram of the overall structure of a dual excitation longitudinal-radial mode conversion high-power ultrasonic vibration system of the present invention;
fig. 2 is a schematic structural diagram of a disc-shaped tool head.
In the figure: 1-a prestressed bolt; 2-rear cover plate; 3a, 3b, 3c, 3 d-electrode plates; 4a, 4b, 4c, 4 d-piezoelectric wafers; 5-thick disk electrode; 6-radial perforation; 7-a flange plate; 8-front cover plate; 9-a horn; 10-a disc-shaped tool head; 10 a-a disc-shaped cutting tool head; 10 b-a disc-shaped welding tool head; 11-a horn; 12-a flange plate; 13-a front cover plate; 14a, 14b, 14c, 14 d-piezoelectric wafers; 15a, 15b, 15c, 15 d-electrode sheet; 16-thick disk electrode; 17-radial perforation; 18-a rear cover plate; 19-prestressed bolt.
Detailed Description
The invention will be described in further detail below with reference to the drawings and examples, which are intended to facilitate the understanding of the invention without limiting it in any way.
As shown in fig. 1, a dual excitation longitudinal-diameter mode conversion high-power ultrasonic vibration system includes a disk-shaped tool head 10 and two thick disk electrode ultrasonic transducers symmetrically arranged on two sides of the disk-shaped tool head 10.
The thick disc electrode ultrasonic transducer on the left side comprises a rear cover plate 2, a first piezoelectric wafer stack (an electrode plate 3a, a piezoelectric wafer 4a, an electrode plate 3b and a piezoelectric wafer 4b), a thick disc electrode 5, a second piezoelectric wafer stack (an electrode plate 3c, a piezoelectric wafer 4c, an electrode plate 3d and a piezoelectric wafer 4d) and a front cover plate 8 which are sequentially connected in series through a prestressed bolt 1. The front cover plate 8 is fixed with the left axle center of a disc-shaped tool head 10 through a horn 9.
The thick disc electrode ultrasonic transducer on the right side has the same structure as the thick disc electrode ultrasonic transducer on the left side, and comprises a rear cover plate 18, a first piezoelectric wafer stack (electrode plate 15d, piezoelectric wafer 14d, electrode plate 15c, piezoelectric wafer 14c), a thick disc electrode 16, a second piezoelectric wafer stack (electrode plate 15b, piezoelectric wafer 14b, electrode plate 15a, piezoelectric wafer 14a) and a front cover plate 13 which are sequentially connected in series through a prestressed bolt 19. The front cover plate 13 is fixed to the right axis of the disc-shaped tool head 10 through the horn 11. The thick disk electrode 5 is uniformly provided with radial through holes 6 along the circumferential surface, and the thick disk electrode 16 is uniformly provided with radial through holes 17 along the circumferential surface.
In this embodiment, to ensure a high effective electromechanical coupling coefficient of the transducer, a thick disk electrode with an appropriate thickness is selected. The thick disc electrodes 5 and 16 are both negative electrodes and are arranged at the vibration displacement nodal planes of the thick disc electrode ultrasonic transducer. The electrode tabs 3a, 3c, 15b and 15d are connected to the negative terminal of the power supply, and the electrode tabs 3b, 3d, 15a and 15c are connected to the positive terminal of the power supply.
The thick disc electrode ultrasonic transducer is provided with flange plates 7 and 12 at the outer part of the vibration displacement joint surface; the transducer can be used as a connecting piece for fixing the transducer, and can also be provided with a bearing, a synchronous pulley or other components.
The front cover plate 8 and the flange 7 of the transducer, and the front cover plate 13 and the flange 12 are all of an integrated structure, and can also be of a split structure. When the split structure is adopted, the two are in interference fit.
The front cover plate 8 and the amplitude transformer 9 of the transducer, and the front cover plate 13 and the amplitude transformer 11 are tightly connected through bolts, and can also be of an integrated structure.
The shape of the horns 9 and 11 is any one of a step shape, a conical shape, an exponential shape, a gaussian shape, etc., and two horns are used to form a secondary horn in cascade in order to further amplify the amplitude.
The amplitude transformer 9 and 11 and the disc-shaped tool head 10 are tightly connected through bolts and can also be of an integrated structure.
When the front cover plate, the amplitude transformer and the circular tool head are connected through bolts, counterbores with internal threads or screws with external threads are arranged at two ends of the amplitude transformer and are used for connecting the front cover plate of the transducer and the circular tool head; both ends of the disc-shaped tool head are provided with counter bores with internal threads or screws with external threads for connecting the amplitude transformer.
As shown in fig. 2, (a) is a disk-shaped cutting tool head 10a, and (b) is a disk-shaped welding tool head 10b, which can be replaced according to the application requirements.
The sectional shapes of the disc-shaped cutting tool head 10a and the disc-shaped welding tool head 10b are any one of power functions, exponents, broken lines, cosine curves, and the like.
The outer end surface of the disc-shaped cutting tool head 10a has a certain edge angle. The outer end face of the disc-shaped welding tool head 10b is provided with fine patterns such as grid patterns, cross patterns, centripetal patterns and the like, and the obtained welding material has different micro-appearances on the surface.
The invention converts the longitudinal vibration of two dual thick disc electrode ultrasonic transducers and an amplitude transformer into the radial vibration of the middle disc-shaped tool head. Because the disc-shaped tool head is taken as the center, the amplitude transformer and the energy converter at the two ends are symmetrically distributed, the disc-shaped tool head generates uniform radial vibration, thereby realizing the rolling welding and cutting of materials.
The embodiments described above are intended to illustrate the technical solutions and advantages of the present invention, and it should be understood that the above-mentioned embodiments are only specific embodiments of the present invention, and are not intended to limit the present invention, and any modifications, additions and equivalents made within the scope of the principles of the present invention should be included in the scope of the present invention.
Claims (9)
1. A dual excitation longitudinal-diameter mode conversion high-power ultrasonic vibration system is characterized by comprising a disk-shaped tool head and two dual thick disk electrode ultrasonic transducers arranged on two sides of the disk-shaped tool head;
the thick disc electrode ultrasonic transducer comprises a rear cover plate, a first piezoelectric wafer stack, a thick disc electrode, a second piezoelectric wafer stack and a front cover plate which are sequentially and tightly connected in series through a prestressed bolt, wherein the front cover plate is fixed with the axis of one side of the disc-shaped tool head through an amplitude transformer; the longitudinal vibration of two pairs of thick disc electrode ultrasonic transducers and amplitude transformers is converted into the radial vibration of the central disc-shaped tool head; the thick disk electrode is uniformly provided with radial through holes along the circumferential surface.
2. The dual excitation longitudinal-diameter mode conversion high power ultrasonic vibration system of claim 1, wherein said thick disk electrode is a negative electrode and is disposed at a vibration displacement nodal plane of the thick disk electrode ultrasonic transducer.
3. The dual-excitation longitudinal-diameter mode-conversion high-power ultrasonic vibration system of claim 1, wherein each of the first piezoelectric wafer stack and the second piezoelectric wafer stack comprises an even number of piezoelectric wafers.
4. The dual excitation longitudinal-diameter mode conversion high power ultrasonic vibration system of claim 1, wherein said thick disc electrode ultrasonic transducer is provided with a flange at the outer part of the vibration displacement nodal plane; the flange plate and the thick disc electrode ultrasonic transducer are of an integrated structure or a split structure, and when the split structure is adopted, the flange plate and the thick disc electrode ultrasonic transducer are in interference fit.
5. The dual excitation longitudinal-radial mode conversion high power ultrasonic vibration system of claim 1, wherein the front cover plate and the horn are of an integral structure, or the front cover plate and the horn are tightly connected through bolts.
6. The dual excitation longitudinal-diameter mode conversion high-power ultrasonic vibration system of claim 1, wherein the horn is a one-stage horn or a multi-stage horn cascade system; the amplitude transformer is in a step shape, a conical shape, an exponential shape or a Gaussian shape.
7. The dual excitation longitudinal-radial mode conversion high power ultrasonic vibration system of claim 1, wherein the horn is integrated with the disc-shaped tool head, or the horn is tightly connected with the disc-shaped tool head through a bolt.
8. The dual excitation longitudinal mode conversion high power ultrasonic vibration system of claim 1, wherein said disc shaped tool heads are a disc shaped welding tool head and a disc shaped cutting tool head, respectively; the outer end face of the disc-shaped welding tool head is provided with grid patterns, cross patterns and centripetal patterns, and the outer end face of the disc-shaped cutting tool head is provided with cutting edges.
9. The dual excitation longitudinal mode conversion high power ultrasonic vibration system of claim 1, wherein the cross-sectional shape of said disc shaped tool head is a power function, an exponent, a polyline or a cosine curve.
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| TW202139583A (en) * | 2020-04-06 | 2021-10-16 | 詠業科技股份有限公司 | Piezoelectric vibration device |
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