JPS6016301A - Superimposed vibratory cutting method - Google Patents

Abstract

PURPOSE:To smooth rough surface of a workpiece and improve precision of machining by applying low frequency vibrations and supersonic vibrations superimposedly to a workpiece or a tool. CONSTITUTION:A cutting tool is caused to make supersonic vibrations (f.a) with the high frequencies in supersonic range above 20kHz in the cutting direction shown by an arrow, and at the same time, it is caused to make vibrations with the low frequencies (F.A) of 100Hz or thereabouts. Vibratory cutting is made with a cutting speed V satisfying the formula V<2piAF on the basis of its connection with the frequencies F of 100Hz vibratory cutting and the maximum speed of vibrations of an amplitude A. After cutting a cutting length LT=V/F during cutting time tc first, said length is mincingly divided with lT=v/f into minute 9, 10, 11. This reduces generation of burs and precise machining can be obtained.

Description

DETAILED DESCRIPTION OF THE INVENTION (Technical Field) The present invention relates to a vibration cutting method in which cutting is performed by vibrating a workpiece or a tool in the cutting direction.

(Prior art) A vibration cutting method that reduces cutting resistance at low cutting speeds compared to conventional cutting and smoothes surface roughness is conventionally known. It is common to strive for improvement. Therefore, the cutting resistance becomes large.

This creates a gap that drives the vibration cutting device with large vibration energy. As for the vibration driving device, an electro-hydraulic type or a mechanical-hydraulic type can produce a larger output than a vibration driving method using a magnetic oscillator or an electric oscillator. Therefore its frequency is 2
It becomes a low frequency of 00Hz or less. After experimenting and putting it into practice, we found that the current technology is the best that satisfies J-axis cutting and dovetail grooves.
The high frequency is considered to be about 1001-1 z.

Cutting length l in one cycle of tool vibration in vibration cutting
T is represented by 4. This IT is an important factor that influences cutting resistance, surface roughness, etc. As is clear from this relational expression, LT at a low frequency of 1001-128 degrees is longer than LT at a high frequency of 2 Of(1-1z) in the ultrasonic range. 20
Comparing with K14z vibration cutting, even if the principal force in two-dimensional cutting shows almost the same value, 20KH
The thrust force of 2-vibration cutting is about 2 to 1/2 of that of 100Hz vibration cutting.
It will be about 6.

In Fig. 1, if the vibration frequency of the cutting tool is increased and the frequency f in the ultrasonic range and the amplitude σ are W, (W, then the back force Pt + cutting time tC + period T of the cutting tool is 5th As shown in the figure, the displacement waveform of the workpiece is linear.For example, pt = 2Kyf.

f = 221<Hz, 'z=n; , k-4,
55×102 to 9f/” +w, = 2 πX 4
00 rad/s, L'-0,10, X= 0
．． It becomes 66 μm.

In this way, when the cutting tool frequency is increased and a pulse cutting waveform is applied, there is no dynamic behavior of the workpiece, and static displacement can be achieved as shown in the figure. ZOl (Hz vibration cutting that utilizes high vibration frequencies in the ultrasonic range has this feature, but magnetic distortion.

When the energy of the electric flexure oscillator is small and the cutting resistance is large, the imaging mode of the cutting tool changes, and in extreme cases, the amplitude of the cutting tool tip becomes zero.

That is, the cutting time t of the pulse cutting force waveform becomes longer, the pulse cutting force waveform peculiar to vibration cutting gradually approaches the conventional cutting force waveform, and the vibration cutting effect disappears.

The deformation waveform of a workpiece in 100Hz dynamic cutting, which can increase the output, is as shown by curve 8. If this curve 8 can be changed linearly as shown in FIG. 5, precision cutting will be possible even during heavy cutting by enlarging the cutting surface and dip during slow cutting. The only concrete way to do this is to reduce the absolute value of P itself and make the behavior of the workpiece due to p insensitive.

Reduction of pt is achieved by drastically reducing LT.

However, the length is determined by LT-, -. In vibration cutting mechanisms to date, the cutting tool has been vibrated at a single frequency, and the LT has been determined in this way, so once the cutting conditions have been determined, it has been treated as an unchanging value.

It was known that the cutting effect could be improved by reducing this LT, but in the past, the LT increased when cutting at low speeds.
It was considered an unavoidable phenomenon.

(Purpose) The present invention aims to reduce the cutting length LT to 2 during the cutting time tc.
0 KHz vibration cutting 7! By subdividing into T, the cutting resistance is drastically reduced and the dynamic behavior of the workpiece is completely eliminated. In other words, as shown in Fig. 6, the cutting tool is subjected to ultrasonic vibration Cf, a) at a high frequency in the ultrasonic range of 20 KHz or more in the cutting direction indicated by the arrow.
Vibrate at a low frequency (F, A) of about 00 Hz,
By relating the cutting speed V to the frequency F of 100 Hz vibration cutting and the maximum vibration speed of amplitude A, the cutting tool is cut by a vibration drive device with a low vibration frequency that can supply a large output by performing vibration cutting as v〈2πAF. First, cut a thick LT=- without disturbing the vibration state of the
The vibration state of the cutting edge tends to be disturbed due to large cutting resistance, so the energy is reinforced by a low frequency stationary drive device, and the imaging state of the cutting edge in the ultrasonic range is stabilized. The cutting force was adjusted to the conventional 1001-1.
It is one digit lower for Z-vibration cutting, and about 1 digit for conventional cutting.

. The purpose is to drastically reduce the surface roughness to a certain extent, smooth the surface roughness, improve machining accuracy, reduce deviations in shape and dimensions after machining, and enable precision machining with fewer burrs.

(Example) FIG. 1 shows a tool-workpiece vibration system in turning processing. As shown in FIG.
A frequency F as low as 001-Izz.

A high vibration Qf with amplitude A and 201(I(z) is vibrated in the direction of 4 with a fixed width α, and υ
Give cutting conditions of 〈2παf or υ〈2πAF. The thrust force p,5 at that time becomes a pulsed cutting force waveform as shown in FIG. t in the figure. is the cutting time during one cycle of the cutting tool, and T is one cycle of vibration of the cutting tool. For 100Hz vibration cutting, it is preferable that the horizontal angular natural vibration of the workpiece + the number w, L is w, ”)w (-2πF). min,'F=
1001 (z, A = 0.2[wn, depth of cut -0
, 20mm, cutting width -1, ()in, rake angle -00
゜w=2πF='l,×lQQ rad/s, W,=
2yrx 360γαd/s, k −= 4.6
×102Kff/++++n, ν=0.055
.

The dynamic behavior of the workpiece in the horizontal direction due to the thrust force P during wet two-dimensional cutting (3sBM) is as shown in Figure 3. behavior.

In precision cutting, the ideal displacement waveform for the workpiece is not the displacement waveform of curve 8 like this, but a straight line with respect to the horizontal time axis as shown in Figure 5, and a displacement of X kO. .

FIG. 9 shows a further cylindrical machining apparatus for carrying out the method of the invention. The apparatus main body 13 is fixed on the lathe carriage 12.

The electric motor 14 is mounted on the main body of the device and the slider 15 is mounted eccentrically.
Rotate with m.

A swinging arm 1 that swings this slider around a central axis 16
7 in the illustrated position so that the swinging arm 17 can vibrate around the central axis 16 with an amplitude equal to the eccentricity of the slider.

A cutting tool holder 24 is fixed to the swinging arm 17 using a tightening bolt, and a diameter reduction sonic vibration system tool consisting of a longitudinal magnetic strain vibrator 18, an amplitude expansion horn 19, and a cutting tool utilizes its vibration nodes. and install it. When the magnetic distortion oscillator 18 is ultrasonically vibrated, the cutting tool blade/tip vibrates at a frequency f in the cutting direction of the arrow 21.

Ultrasonic movement is performed with an amplitude a of 10 μm or more in half amplitude.

When the electric motor 14 is rotated and the vibrating arm 17 is vibrated, the Hyde cutting edge moves in the cutting direction of the arrow 22 with a frequency of F9 and a single amplitude of 0.
It vibrates at a low frequency with an amplitude A of about 2K. In this way, the superimposed vibration cutting tool 20 is produced, and the present invention can be put into practice.

The workpiece 244 is then rotated at a cutting speed V in the direction of arrow 28. The cutting speed υ is selected so that υ〈2πAP. By applying wide feed in the direction of the arrow 26 to the hide as shown in the figure and cutting with such a device and cutting conditions, it is possible to perform two-dimensional cutting and vertical feed according to the present invention to perform cylindrical turning. .

According to the present invention, the chip shape is 9,10°11.
The block is divided into Glocks with a length proportional to LT, and the block is further divided into +I+ fields with a length proportional to LT, and then discharged.

(Effects) According to the method of the present invention, the cutting resistance P' is drastically reduced as shown in FIG. For example, stainless steel SUS 304.

Width 1mm, cutting speed -〇, 8m/min, depth of cut 0.
2mm.

J, "" 1001 (z, A= 0-15 nun
, f = 201 (Hz, a = 15 μm, rake angle -〇° wet two-dimensional cutting and only 100 Hz vibration cutting, the average thrust force p = 1.8 kg is almost zero by the superimposed vibration cutting of the present invention. The result is 0.4 Kr, which is close to 0.4 Kr.Another noteworthy effect is that the principal force p, which has been desired for many years, has slightly decreased from 1001 (z) to 61 (9 in the case of vibration cutting only) to 0.6 Kr. did.

Therefore, the displacement of the workpiece becomes a static displacement and shows a straight line with respect to the time axis as shown in FIG. The amount of displacement x' is 20
It is equivalent to or lower than Kl-12 vibration cutting.

By implementing the present invention, the average thrust force = 0.2 Ky could be reduced to principal force = 0.4 Ky, and the thrust force = 7 for the thrust car 01.

There is still no burr on the end face, and the surface roughness is 0.8.
μm l (max).

Next, the effects of the present invention will be explained by illustrating other machining methods and methods of applying the present invention to other tools. Figure 10 shows the case where the cutting tool is moved in the cutting direction f-a, F.
−A, cutting speed V is υ〈2πAl”,
Plane.

As a 100 H,z vibration seat motion device, there are mechanical and electric types.
Hydraulic, mechanical-hydraulic, pneumatic, and electric types are available.

20 K1-1 As the z-vibration drive device, vertical eye movement or torsional vibration magnetoflexion, longitudinal vibration system Hyde using an electric oscillation vibrator, vibration-based bite, and torsional vibration-system Hyde can be used for music. With this method and device, it has become possible to immerse and flatten highly elastic workpieces such as combs and carbon fiber reinforced plastics.

Fig. 11 shows a case in which the hacksaw blade 27 is vibrated at a cutting speed of f-a, F-A, and the cutting speed υ is applied to a saw blade.
With υ〈2πAF, -cutting is performed by applying a foot load of 7 mm. To apply pressure at this time, the workpiece may be vibrated at F and A, and the saw blade may be vibrated at fa. And the same implementation effect can be obtained. There are still cases where the workpiece is vibrated at f-a and the saw blade is vibrated at flct and f-a to make a new superimposed cut. This method and device enable crystal-tight cutting of ceramics.

By carrying out the present invention with this method and device, the time required for cutting with a metal knife is shortened, the cut surface becomes flat/1'f, and a cutting effect that does not cause chipping can be obtained.

FIG. 1z 74 shows a case where the broach 28 is applied.

Up until now, we have conducted research on applying 201(i(z) vibration cutting alone and on broach cutting using 1001-Iz vibration cutting, but in the case of 20 and 11z vibration cutting,
The effect of lack of vibration energy is reduced, ■00H2
In the case of vibration cutting, satisfactory effects were not obtained, such as the surface roughness being not smooth. By applying the present invention to broach cutting, the principal force P becomes almost zero, which is the decisive effect in cutting processing, and the surface roughness is flattened to t1.
The effect of "I" was exhibited at the same time, making ideal broach cutting possible.

FIG. 18 shows the case where it is applied to Yasu IJ 29.

The file is also a surface brooch. There is an extremely large amount of manual work with files. And it is difficult to finish the inner surface of a deep hole in a hard material. When filing, you want to reduce cutting resistance and finish in a short time. By implementing the present invention, this problem up to now can be resolved and eliminated. The present invention is carried out by vibrating the file superimposedly in the longitudinal direction of the file at f-a and F-A, and setting the machining speed fij-v to V<ZπA li''.The pressing force P is reduced, and the work time is shortened by 1 hour. This reduces labor and makes the filing work easier.Instead of this file, if the present invention is applied to a scraper with a cutting edge at the tip, the scraping work can be done by superimposed video cutting, making the scraping work more efficient. It has the effect of improving machining accuracy and reducing labor.

FIG. 14 shows a case where the present invention is applied to a thread cutting tool 30. The cutting area in this thread cutting is wider than the cutting area in the cylindrical machining of Hsutsu. As a result, cutting resistance increases. Conventionally, when thread cutting, 2° Kl-IZ vibration cutting has been performed with emphasis on the precision of the cutting surface. Therefore, the cutting area is divided into smaller sections to minimize the cutting resistance acting on the cutting edge, thereby disturbing the vibrational state of the cutting edge and performing vibration cutting under various cutting conditions. Cutting threads into hardened steel and other materials required quite a long processing time. Implementation of the present invention reduces the processing time,
It becomes possible to mass-produce highly accurate screws.

In addition to this, for general reaming and center reaming, the reamer is vibrated by ultrasonic torsion in the circumferential direction using a torsional vibrator, and at the same time mechanical or pneumatic methods are used.

The present invention is carried out by applying circumferential vibration and rotational motion by hydraulic, electric, and electro-hydraulic methods, and a superimposed vibration reaming effect is obtained to perform ultra-precision machining of holes.

If applied to a drill instead of a reamer, superimposed vibration IJI
J-song results can be obtained and precision drilling of holes can be performed.

In addition, in milling with a milling machine, if the milling cutter or end mill is vibrated by ultrasonic torsion in the circumferential direction with a torsional vibrator, mechanical, pneumatic, hydraulic, etc.
The present invention is carried out by using an electro-hydraulic method to generate circumferential vibration and rotational motion, and the effect of superimposed follow-up milling or superimposed end milling can be obtained to perform bonding and flat processing. .

Figure 15 shows how to mass produce a thin plate material into a cross-sectional shape that cannot be processed by punching by sending a cutting tool in a direction perpendicular to the burr and punching direction that appears on the end surface of a workpiece that has been punched and plastically processed. This is a case where it is applied to part-time jobs.

The cutting edge shape at this time is the total cutting edge shape as shown in the figure, and the cutting surface A 82 thereof is generally wide. Therefore, the cutting resistance increases. Since it is necessary to completely eliminate the occurrence of burrs, it is necessary to cut with almost zero cutting resistance, which is closely related to burrs.

By implementing the present invention, these problems can be solved all at once by 1Q' (
It will be decided.

SUS304. , plate thickness 0.3mm is υ-30011
1111/lrr, i 71. .

Cutting area 0.5 am2. F = 1001(z,
A = 0.15 mm.

f = 201(1-(z, a-,15am (
D. By carrying out the present invention, the side surface of the punched hole is punched into a curved surface as shown in the figure by superimposed vibration cutting, and the mass-produced workpiece is precisely machined without any burrs. It was very successful.

FIG. 16 shows a case where the present invention is applied to a cutting blade 33.

In this case as well, the blade 88 is vibrated in the cutting direction at a frequency F and amplitude a of about 100) 1z and an amplitude A% of 20 Kl-Iz or more, and the cutting speed V is set to I/<2π.
Superimposed vibration cutting is performed as AF. By implementing the present invention, even when cutting a thick plate, most of the cross section can be cut by shear deformation, and the cut surface can be processed to have a smooth cross section.

FIG. 17 shows a case in which the present invention is applied to a punch when punching is performed using a punch and a die. Conventionally, vibration punching has been attempted by applying ultrasonic vibrations of 20 Kl-Iz or more to a punch, but the ultrasonic vibrations of the punch tend to stop due to lack of vibration energy, and the work cloth is rough and the ultrasonic vibrations are not applied. Although the effect was not enough, I was disappointed. To this day, we have been eagerly awaiting the creation of an ultrasonic transducer with high output, but no vine transducer has yet been completed that meets those expectations.

However, with the present invention, a new energy usage method that combines a conventional vibrator and a low-frequency vibration drive device has been used to punch punches weighing several tons. A path to application has been opened.

That is, the punch 83 is vibrated in the punching direction at an ultrasonic frequency f and an amplitude a using a magnetic or electric flexure vibrator, and this is vibrated at 1oaf-Iz by an electro-hydraulic system.
Moderate vibration &! The invention is implemented by vibrating and punching at IF and amplitude A. Then, the vibration mode of the punch during processing vibrates without being disturbed, and by repeating small shear deformation by the above-mentioned vibration cutting mechanism, the entire processed cross section can be punched by uniform shear deformation.

[Brief explanation of the drawing]

Figure 1 shows a modeled tool-workpiece vibration system in turning processing, and explains all vibration directions of the tool, and Figure 2 shows 1001 (z vibration cutting F,
A diagram showing a pulsed thrust force waveform with a relatively long action time 1c during a cycle. Figure 3 shows the direction of the thrust force on the workpiece when the pulsed thrust force waveform in Figure 2 acts on the workpiece. Figure 4 shows the curved dynamic behavior waveform of 'fi 201 (I-1
Figure 5 shows a pulsed thrust force waveform with a very short action time tc during one cycle of vibration of the cutting tool in z-swing cutting f-a. A diagram showing a linear displacement waveform in the direction of back force of a workpiece when it acts on an object, FIG. 6 is a diagonal view of a chip shear cross section obtained by the method of the present invention, and FIG. Figure 8 is a diagram showing the intense and threatening pulsed thrust force obtained by this method. Figure 8 shows the linear displacement waveform in the direction of the thrust force, which decreases dramatically when the pulsed thrust force waveform in Figure 7 acts on the workpiece. FIG. 9 is a front view of an embodiment of an apparatus for carrying out the method of the present invention, FIG. 10 is a diagram showing a method for cutting according to the method of the present invention, and FIG. Diagram showing the cutting method, 1st
21 yen 1 is a diagram showing a broaching method using a broach according to method V of the present invention, FIG. 13 is a diagram showing a filing method using a file according to the method of the present invention, and FIG. Fig. 15 shows a method of forming a curved surface in a direction perpendicular to the punching direction using a total amount of hide and a punch according to the method of the present invention. Diagram 171: !!J is a diagram showing the entire machining method. 41...Bite, 2...Workpiece, 3...Cutting speed,
4... Vibration direction, 21... Ultrasonic vibration direction, 22
...Low 1, LJ wave vibration direction, 27...Superimposed vibration cutting saw blade, 28...Heavy-vibration cutting broach, 29.
・・Heavy beating vibration cutting file, 80 ・・Heavy vibration cutting cutting tool, 81 ・・Superimposed vibration cutting general type tool,
82...Punch for superimposed vibration cutting and punching. Figure 6 11 Figure 7 Figure 8 Figure 15

Claims (1)

[Claims] A workpiece or tool is subjected to low-frequency imaging at low frequency F and amplitude A and ultrasonic frequency 1. A superimposed vibration cutting method in which ultrasonic imaging with amplitude a is superimposed to vibrate in the cutting direction, and cutting is performed at a cutting speed V of υ<2πAF, which is lower than the maximum vibration speed of low circumferential speed vibration.