CN116079499A - Vibration measurement method and system for tool in rotary ultrasonic machining - Google Patents

Vibration measurement method and system for tool in rotary ultrasonic machining Download PDF

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Publication number
CN116079499A
CN116079499A CN202211088405.6A CN202211088405A CN116079499A CN 116079499 A CN116079499 A CN 116079499A CN 202211088405 A CN202211088405 A CN 202211088405A CN 116079499 A CN116079499 A CN 116079499A
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tool
sound pressure
frequency
vibration
cutter
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宫虎
孙艺嘉
桂淑钰
敖圣钧
倪皓
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Tianjin University
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Tianjin University
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    • BPERFORMING OPERATIONS; TRANSPORTING
    • B23MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23QDETAILS, 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
    • B23Q17/00Arrangements for observing, indicating or measuring on machine tools
    • B23Q17/12Arrangements for observing, indicating or measuring on machine tools for indicating or measuring vibration

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  • Mechanical Engineering (AREA)
  • Measurement Of Mechanical Vibrations Or Ultrasonic Waves (AREA)

Abstract

The invention belongs to the technical field of rotary ultrasonic processing vibration detection, and relates to a method and a system for measuring cutter vibration in a rotary ultrasonic processing system, in particular to a rotary ultrasonic processing system working in a non-full resonance state. The vibration of the tool is characterized by measuring the sound pressure amplitude of the tool radiation. The invention can realize the determination of the working frequency of the vibration system and the in-situ measurement of the change of the vibration of the same cutter under the fixed frequency. The invention can represent the vibration of the cutter during idle load and also can represent the vibration of the cutter during processing.

Description

Vibration measurement method and system for tool in rotary ultrasonic machining
Technical Field
The invention belongs to the technical field of rotary ultrasonic processing vibration detection, and particularly relates to an ultrasonic vibration measurement method and system for a cutter in rotary ultrasonic processing.
Background
In rotary ultrasonic machining, in order to effectively utilize ultrasonic vibrations, the entire vibration unit should ideally operate at the same resonant frequency, maximizing its energy conversion efficiency, including the electrical resonant frequency of the vibration system and the mechanical resonant frequency of the mechanical vibration unit (transducer and tool). However, due to practical requirements, a rotary ultrasonic machining system needs to accommodate various tools. In order to improve the ability of the ultrasonic vibration unit to accommodate a variety of tools, ultrasonic transducers (including horns) are designed to hold differently shaped tools. The resonant frequencies of the ultrasonic transducer and the tool are often non-uniform. That is, the ultrasonic vibration unit is configured to generate a vibration of a relatively maximum intensity at a certain excitation frequency in a non-full resonance state.
Typically, once the tool is replaced or reloaded (tool length change), the vibration characteristics of the tool will change significantly, requiring a recalibration of the operating frequency to obtain optimal tool vibration. It is therefore necessary and important to build an operating frequency measurement system for a rotary ultrasonic machining system. When the working frequency is determined, the vibration of the cutter at different excitation voltages needs to be measured to provide a reference for optimizing vibration parameters. Essentially, the magnitude of the tool vibration is characterized, either by the operating frequency determination of the vibration system or by a measurement of the relative magnitude of the tool vibration.
Currently, the magnitude of tool vibration is typically characterized by measuring the displacement of certain key points on the tool or the average displacement of the tool in certain directions. Three types of optical-based measuring systems, laser displacement sensors, laser interferometers, and laser doppler meters, are the most common methods for measuring the vibrational displacement of a tool. However, when measuring a tool having a complicated structure such as a twist drill, a micro milling cutter, etc., the conventional optical measuring system is difficult to operate with respect to light due to a large change in curvature of the surface to be measured or a small area of the surface to be measured, and it is difficult to perform measurement. And the optical measurement system is very expensive and is easy to be disturbed by the environment. In addition to optical measurement systems, capacitive sensors and eddy current sensors can also measure object vibration displacements. However, the technical problem is that the two sensors measure the output value and the vibration of the tool without necessarily being linked due to the limitation of the measuring principle and the complex shape of the bottom surface of the tool. In addition, during machining, the tool may come into contact with the workpiece, and the displacement sensor may not measure vibration of the tool during machining.
Another approach is to reflect the tool vibrations by measuring an electrical signal across the vibration system. In the existing detection system and method, the working frequency is determined by mapping a amplitude-frequency curve and a phase-frequency curve for a selected vibration system through a network analyzer. And the frequency tracking is realized by tracking the phase through a phase-locked loop circuit. However, the vibrations of the tool are affected not only by the input electrical power, but also by the geometry of the vibration system. For an ultrasonic vibration unit in a non-full resonance state, the electrical resonance frequency thereof is not necessarily the frequency at which the tool end portion vibrates maximally. The measurement system based on electricity is mainly applied to the determination of the working frequency of the ultrasonic vibration unit in the full resonance state of the fixed structure. Moreover, the magnitude of the tool vibration at the same vibration frequency cannot be directly reflected.
According to the technical background, a measuring method and a measuring system which can economically and effectively realize the in-situ measurement of the vibration of the cutter in the rotary ultrasonic processing system, including the determination of the working frequency of the cutter and the relative measurement of the vibration of the cutter under the working frequency are not available at present.
Disclosure of Invention
The invention aims to overcome the defects of the prior art and provide a method and a system for determining the working frequency of cutters with various shapes, particularly cutters with complex geometric shapes and measuring the relative vibration of the cutters at the working frequency, which can be suitable for a rotary ultrasonic processing system working in a non-full resonance state. The method comprises the steps of determining the working frequency of a tool vibration system in an industrial site by measuring the sound pressure amplitude of tool radiation and characterizing the relative change of tool vibration at the working frequency. Under different vibration frequencies, the frequency corresponding to the maximum value of the maximum sound pressure radiated by the cutter along the axis is the working frequency of the cutter.
The vibration state of the tool has a very important influence on the processing quality and processing efficiency of the rotary ultrasonic processing. In order to increase the energy transmission efficiency of the vibration system, it is necessary to determine the operating frequency of the tool so that the tool operates at the frequency at which the end vibration is maximum. When the working frequency is determined, the vibration of the cutter at different excitation voltages needs to be measured to provide a reference for optimizing vibration parameters. In addition, since the quality of the machining is closely related to the magnitude of the tool vibration, the change in the tool vibration during the machining process is also monitored. Essentially, it is necessary to characterize the magnitude of the tool vibrations, whether the operating frequency of the vibration system is determined or the relative magnitudes of the tool vibrations at different vibration states are measured.
The technical scheme adopted for solving the technical problems is as follows:
a first aspect of the present invention provides a vibration measurement method for a tool in rotary ultrasonic machining, by measuring the sound pressure amplitude of the tool radiation to determine the operating frequency of the tool vibration system and characterize the magnitude of the vibrations of the tool.
The complete measurement method comprises the following steps: first, a range of tool operating frequencies is given, at each frequency, a maximum sound pressure amplitude (hereinafter, we collectively refer to as peak sound pressure) is searched in the direction of the tool axis, and then the relative magnitudes of the peak sound pressures at different frequencies are compared. The frequency corresponding to the maximum value of the peak sound pressure is the working frequency of the cutter.
Considering the narrow bandwidth energy concentration of the ultrasonic vibration unit in ultrasonic processing, the measurement method can be simplified as follows: firstly, measuring the response of sound pressure amplitude at a specific position along with the change of frequency, and determining a candidate value of the working frequency according to the extreme point of a sound pressure amplitude-frequency curve. Then, the peak sound pressure at the candidate frequency is measured again, and the working frequency of the tool vibration system and the vibration size describing the tool are determined by the relative size of the peak sound pressure. The frequency corresponding to the maximum peak sound pressure is the working frequency of the cutter. The peak sound pressure can quantitatively describe the magnitude of the vibration of the tool at a fixed frequency.
The acoustic pressure signal collected by the sensor may contain a lot of noise considering other signal disturbances in the industrial field, and filtering of the collected acoustic pressure signal is required in order to improve the interference immunity of the measuring system. Because the frequency of the sound pressure signal radiated by the cutter is single and the frequency of the sound pressure signal is the same as that of the excitation signal, the band-pass filter with the center frequency synchronously changing along with the excitation signal is arranged in the signal processing circuit module, so that the accurate extraction of the sound pressure amplitude of the cutter radiation is realized.
A second aspect of the present invention provides a measurement system for implementing the above measurement method, comprising:
the computer controls the ultrasonic power supply to output electric signals with continuously changing frequency, the electric signals with different frequencies excite the cutter to radiate sound pressure signals with different magnitudes, and a curve of sound pressure amplitude along with the change of frequency is drawn according to the sound pressure signals with different frequencies;
and the singlechip is connected with the computer.
The displacement platform is controlled by the singlechip to move;
the microphone is fixed on the displacement table through a clamp and collects sound pressure signals radiated by the cutter;
and the signal processing circuit module is used for amplifying, filtering and analog-to-digital converting the signals of the microphone and then inputting the signals into the computer.
Further, the microphone is mounted at a designated position around the cutter side edge. Or the microphone is arranged on the bottom surface of the cutter and is coaxial with the cutter along the axial direction of the cutter.
The invention can realize the determination of the working frequency of the vibration system and the online measurement of the change of the vibration of the same cutter under the fixed frequency. The measurement of the vibration of the tool may be the vibration of the tool when the tool is empty, or the vibration of the tool during processing.
The invention has the advantages and positive effects that:
(1) The invention can realize in-situ measurement of cutter vibration on industrial site, and has convenient and efficient operation and low cost of the measuring system.
(2) The invention can realize the determination of the working frequency of cutters of various shapes in a rotary ultrasonic processing system working in a non-full resonance state.
(3) The invention can efficiently and relatively accurately measure the working frequency of complex cutters with complex structures, such as twist drills, micro milling cutters, ball end milling cutters and the like, which cannot be realized by the current invention.
(4) When the working frequency of the cutter is fixed and the relative size of the cutter vibration is represented, the invention can reflect the relative size of the cutter vibration in an unprocessed state and also can change the cutter vibration in the processing process.
(5) The invention has simple operation, and can conveniently determine the working frequency of the vibration system and then characterize the relative vibration of the cutter at the working frequency every time the cutter is replaced in the rotary ultrasonic processing system.
Drawings
FIG. 1 is an overall block diagram of a measurement system according to an embodiment of the invention;
FIG. 2 is a flow chart of a measurement method according to an embodiment of the invention;
FIG. 3 is a geometric model of six typical tools;
FIG. 4 is a sound field distribution diagram of six tools;
FIG. 5 is a graph of sound pressure as a function of measurement location and excitation frequency;
FIG. 6 is a graph of sound pressure amplitude versus distance for a face milling cutter at different frequencies;
FIG. 7 is a graph of sound pressure at different excitation voltages;
fig. 8 is a calibration chart of working frequency of the face milling cutter in industrial field, wherein (a) is an in-situ measurement field chart of cutter vibration of the face milling cutter when no load is applied, (b) is a measurement field chart of vibration of the twist drill when cutting is applied, and (c) is a calibration process chart of working frequency of the cutter.
Detailed Description
It should be noted that, in the case of no conflict, the embodiments and features in the embodiments may be combined with each other. The invention will be described in detail below with reference to the drawings in connection with embodiments.
It is noted that all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this application belongs unless otherwise indicated.
The invention provides a vibration measuring method for a cutter in rotary ultrasonic processing, which is used for determining the working frequency of a cutter vibration system and describing the vibration size of the cutter by measuring the sound pressure amplitude of cutter radiation. The amplitude of the first maximum sound pressure value (hereinafter, we collectively refer to as peak sound pressure) occurring on the tool axis near the end of the tool bottom surface is selected as a parameter reflecting the tool vibration according to the rule that the sound energy radiated from the tool is mainly concentrated on the tool axis and the sound pressure distribution on the tool axis.
The measurement system is shown in fig. 1, and includes: computer, singlechip, displacement platform, microphone. The computer controls the ultrasonic power supply to output electric signals with continuously changing frequency, the electric signals with different frequencies excite the cutter to radiate sound pressure signals with different magnitudes, and a curve of sound pressure amplitude along with the change of frequency is drawn according to the sound pressure signals with different frequencies; the computer is connected with the displacement table through the singlechip, the microphone is fixed on the displacement table through the clamp, and the microphone is coaxially arranged with the cutter along the axial direction of the cutter to collect the sound pressure signal radiated by the cutter; the collected sound pressure signals are input into the computer for storage through amplification, filtering analog-to-digital conversion and other processes of the signal processing circuit module.
To improve the signal-to-noise ratio of the pick-up signal, the microphone may be measured at a position near the bottom surface of the tool. The collected signals are input into a computer for storage through the processes of amplification, analog-to-digital conversion and the like of the signal processing circuit module. And then, the computer draws a curve of sound pressure amplitude along with the change of frequency according to the sound pressure signals at different frequencies. When the curve has only one maximum, the working frequency of the cutter is the frequency corresponding to the maximum. When the curve has more than one maximum value, the curve of the sound pressure amplitude varying with the distance needs to be further measured at the frequency corresponding to the maximum value in order to obtain the sound pressure peak value due to the fluctuation of the sound pressure amplitude varying with the distance. From the curve of the sound pressure amplitude as a function of distance, we can determine the relative magnitude of the sound pressure peak, and thus the operating frequency of the tool.
The specific measurement method is shown in fig. 2: firstly, setting an excitation frequency range and an initial position of a sliding displacement table, and controlling an ultrasonic power supply to output electric signals with continuously changing frequencies by a computer, wherein the electric signals with different frequencies excite a cutter to radiate sound pressure signals with different magnitudes. The microphone is fixed on the displacement table through the clamp, is coaxially arranged with the cutter along the axial direction of the cutter, and collects the sound pressure signal radiated by the cutter. To improve the signal-to-noise ratio of the pick-up signal, the microphone may be measured at a position near the bottom surface of the tool. Signals collected by the microphone are input into a computer through a data collection card, and signal peaks are extracted after band-pass filtering. The center frequency of the band-pass filter is adjusted in real time according to the frequency of the excitation signal. And then, the computer draws a curve of sound pressure amplitude along with the change of frequency according to the signal peak values under different frequencies. When the curve has only one maximum, the working frequency of the cutter is the frequency corresponding to the maximum. When the curve is more than one maximum, in order to obtain the peak sound pressure, it is necessary to further measure the curve of the sound pressure signal with the distance at the frequency corresponding to the maximum. By comparing peak sound pressures at different frequencies, the excitation frequency corresponding to the maximum peak sound pressure is the working frequency of the cutter. After the working frequency is determined, the sound pressure signal under the distance corresponding to the peak sound pressure is measured, so that the vibration of the cutter under different voltages can be represented. In addition, in order to prevent interference during machining, a microphone may be installed at a certain position around the cutter side edge to monitor cutter vibration.
The sound field of six types of typical cutters are analyzed in the embodiment of the application, and as shown in fig. 3, the cutters are respectively a flat head milling cutter, a ball head milling cutter, a hollow cutter, a twist drill, a full-tooth thread milling cutter and a three-tooth thread milling cutter.
Fig. 4 shows the sound field distribution in cross section when the tool is subjected to axial mechanical excitation. The excitation frequency in the figure is the tool resonant frequency. As can be seen from fig. 4, the acoustic energy of the tool radiation radiated from the six types of tools is mainly concentrated in the region near the bottom edge of the tool, and the sound field radiated from the tool has strong directivity in the axial direction. In the region shown in fig. 4, the maximum value of the sound pressure radiated by other tools than the twist drill is at or near the axis. The maximum value of the sound pressure of the twist drill on the axis is also relatively large. Based on this, the present invention selects the peak sound pressure on the tool axis as an index for measuring the tool vibration.
Because of the mutual interference of sound waves radiated by each point source on the cutter, along the axial direction, the sound pressure amplitude attenuates with the fluctuation along with the increase of the distance, and the positions of the sound pressure peaks radiated by different cutters are different. However, in most positions, the sound pressure amplitude of the radiation of the tool at the resonant frequency is typically greater than the sound pressure amplitude of the radiation of the tool at the non-resonant frequency at the same distance, as shown in fig. 5. This is mainly because the ultrasonic vibration system applied to the process is generally designed to have a small bandwidth and a concentrated energy. Fig. 6 shows more clearly the variation of sound pressure amplitude with distance for a face milling cutter at different frequencies. In addition, in actual measurement, since the actual microphone has a certain size, an average value of sound pressure in a certain area is reflected. Therefore, at the time of actual measurement, the maximum value of the peak sound pressure amplitude-frequency curve and the frequency corresponding to the maximum value reached on the sound pressure amplitude-curvature curve at a certain fixed position are substantially uniform. The maximum corresponding frequency of the peak sound pressure with the frequency variation can be obtained by first obtaining the maximum frequency of the sound pressure amplitude at a certain position. Then, the maximum value of the peak sound pressure at the different polarity value frequencies is compared to determine the operating frequency of the vibration system. After the operating frequency of the vibration system is determined, the change of the vibration of the same cutter is quantitatively described by measuring the peak sound pressure value.
Fig. 8 (a) shows an in-situ measurement field of the tool vibration of the face milling cutter when empty and fig. 8 (b) shows a measurement field of the vibration of the twist drill when cutting.
Fig. 8 (c) shows in detail the calibration of the tool operating frequency, taking a face milling cutter as an example. Firstly, the microphone is placed coaxially with the cutter at a position 1mm away from the bottom surface of the cutter, and collects a sound pressure signal at the position 1 mm. The sweep frequency range of the ultrasonic power supply is set to be 20kHz-45kHz, and the step distance is 500Hz. From the curve of the sound pressure amplitude with the frequency, the sound pressure amplitude has two maxima in the frequency range of 20kHz-45kHz, 31.5kHz and 40.5kHz respectively. Then, the sound pressure signals at different positions are measured by moving the position of the displacement table, the moving range of the displacement table is set to be 0-10mm, and the step distance is set to be 0.5mm. From the curves of the sound pressure amplitude values with the distance at the two frequencies, the sound pressure peak value of 40.5kHz is larger than the sound pressure peak value of 31.5 kHz. From this, the operating frequency of the milling cutter was found to be 40.5kHz. The magnitude of the tool vibration can be quantitatively described by using the peak sound pressure.
Measurement of the relative change in tool vibration during machining. During machining, the tool always vibrates at a single frequency. The magnitude of the vibrations of the tool may change under different load conditions. At this time, similar to the sound field law of the cutter radiation under different excitation voltages, the sound pressure distribution of the cutter radiation is basically unchanged, and the sound pressure amplitude is changed. In order to monitor the vibrations of the tool under the influence of different loads, the microphone is fixed in a certain position near the tool by means of a clamp for measuring the sound pressure signal radiated by the tool.
The above description is only of the preferred embodiments of the present invention and is not intended to limit the present invention, but various modifications and variations can be made to the present invention by those skilled in the art. Any modification, equivalent replacement, improvement, etc. made within the spirit and principle of the present invention should be included in the protection scope of the present invention.

Claims (6)

1. A vibration measurement method for a tool in rotary ultrasonic machining, characterized in that the operating frequency of the tool vibration system and the variation of the vibration magnitude characterizing the tool during machining are determined by measuring the sound pressure amplitude of the tool radiation.
2. The method according to claim 1, characterized in that firstly the response of the sound pressure amplitude at a specific location to the change of frequency is measured, the candidate value of the operating frequency is determined on the basis of the extreme point of the sound pressure amplitude-frequency curve, and then the peak sound pressure at the operating frequency is measured, and the operating frequency of the tool vibration system and the vibration describing the tool are determined from the relative magnitudes of the peak sound pressures.
3. The method of claim 2, wherein when one maximum of the sound pressure amplitude-frequency curve is substantially greater than the other maxima, the operating frequency of the tool is the frequency corresponding to the maximum; when the sound pressure amplitude-frequency curve has a plurality of maxima with little phase difference, the curve of the sound pressure signal along with the distance change under the frequency corresponding to the maxima needs to be further measured, and the frequency corresponding to the maximum peak sound pressure is the working frequency of the cutter by comparing the peak sound pressures under different frequencies.
4. A measurement system for carrying out the measurement method of claim 1 or 2 or 3, comprising:
the computer controls the ultrasonic power supply to output electric signals with continuously changing frequency, the electric signals with different frequencies excite the cutter to radiate sound pressure signals with different magnitudes, and a curve of sound pressure amplitude along with the change of frequency is drawn according to the sound pressure signals with different frequencies;
the singlechip is connected with the computer;
the displacement platform is controlled by the singlechip to move;
the microphone is fixed on the displacement table through a clamp and collects sound pressure signals radiated by the cutter;
and the signal processing circuit module is used for amplifying, filtering and analog-to-digital converting the signals of the microphone and then inputting the signals into the computer.
5. The system of claim 4, wherein the microphone is mounted at a designated location about the cutter side edge.
6. The system of claim 4, wherein the microphone is mounted on the bottom surface of the tool and is coaxial with the tool along the axis of the tool.
CN202211088405.6A 2022-09-07 2022-09-07 Vibration measurement method and system for tool in rotary ultrasonic machining Pending CN116079499A (en)

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Citations (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JP2008085271A (en) * 2006-09-29 2008-04-10 Disco Abrasive Syst Ltd Method of setting frequency of ultrasonic vibration given to cutting blade and cutting device
CN103997706A (en) * 2014-04-24 2014-08-20 歌尔声学股份有限公司 Method and system for acquiring natural frequency of vibration diaphragm
CN106670894A (en) * 2017-03-11 2017-05-17 河南理工大学 Ultrasonic torsional vibration measuring device and measuring method thereof
CN107850484A (en) * 2015-07-08 2018-03-27 萨奥有限公司 Method and apparatus for the resonant frequency of the instrument that measures ultrasonic vibrating machining
CN113091283A (en) * 2021-04-07 2021-07-09 青岛海尔空调器有限总公司 Compressor working frequency control method and device, air conditioner, storage medium and product
CN115022788A (en) * 2022-08-03 2022-09-06 杭州兆华电子股份有限公司 Vibrating diaphragm tension device for controlling measuring microphone and vibrating diaphragm method thereof
CN115014502A (en) * 2022-08-04 2022-09-06 南京木木西里科技有限公司 Real-time amplitude automatic measurement system of ultrasonic knife

Patent Citations (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JP2008085271A (en) * 2006-09-29 2008-04-10 Disco Abrasive Syst Ltd Method of setting frequency of ultrasonic vibration given to cutting blade and cutting device
CN103997706A (en) * 2014-04-24 2014-08-20 歌尔声学股份有限公司 Method and system for acquiring natural frequency of vibration diaphragm
CN107850484A (en) * 2015-07-08 2018-03-27 萨奥有限公司 Method and apparatus for the resonant frequency of the instrument that measures ultrasonic vibrating machining
CN106670894A (en) * 2017-03-11 2017-05-17 河南理工大学 Ultrasonic torsional vibration measuring device and measuring method thereof
CN113091283A (en) * 2021-04-07 2021-07-09 青岛海尔空调器有限总公司 Compressor working frequency control method and device, air conditioner, storage medium and product
CN115022788A (en) * 2022-08-03 2022-09-06 杭州兆华电子股份有限公司 Vibrating diaphragm tension device for controlling measuring microphone and vibrating diaphragm method thereof
CN115014502A (en) * 2022-08-04 2022-09-06 南京木木西里科技有限公司 Real-time amplitude automatic measurement system of ultrasonic knife

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