WO2019161743A1 - 一种蜂窝芯超声切削刀柄 - Google Patents

一种蜂窝芯超声切削刀柄 Download PDF

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Publication number
WO2019161743A1
WO2019161743A1 PCT/CN2019/074603 CN2019074603W WO2019161743A1 WO 2019161743 A1 WO2019161743 A1 WO 2019161743A1 CN 2019074603 W CN2019074603 W CN 2019074603W WO 2019161743 A1 WO2019161743 A1 WO 2019161743A1
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WO
WIPO (PCT)
Prior art keywords
horn
positive
hole
ultrasonic cutting
shank
Prior art date
Application number
PCT/CN2019/074603
Other languages
English (en)
French (fr)
Inventor
康仁科
董志刚
王毅丹
朱祥龙
高尚
鲍岩
Original Assignee
大连理工大学
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Priority claimed from CN201810157271.6A external-priority patent/CN108356298B/zh
Priority claimed from CN201810157223.7A external-priority patent/CN108436184B/zh
Application filed by 大连理工大学 filed Critical 大连理工大学
Priority to EP19756842.1A priority Critical patent/EP3756808B1/en
Priority to US16/968,122 priority patent/US11220018B2/en
Publication of WO2019161743A1 publication Critical patent/WO2019161743A1/zh

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B26—HAND CUTTING TOOLS; CUTTING; SEVERING
    • B26D—CUTTING; DETAILS COMMON TO MACHINES FOR PERFORATING, PUNCHING, CUTTING-OUT, STAMPING-OUT OR SEVERING
    • B26D7/00—Details of apparatus for cutting, cutting-out, stamping-out, punching, perforating, or severing by means other than cutting
    • B26D7/08—Means for treating work or cutting member to facilitate cutting
    • B26D7/086—Means for treating work or cutting member to facilitate cutting by vibrating, e.g. ultrasonically
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B06—GENERATING OR TRANSMITTING MECHANICAL VIBRATIONS IN GENERAL
    • B06B—METHODS OR APPARATUS FOR GENERATING OR TRANSMITTING MECHANICAL VIBRATIONS OF INFRASONIC, SONIC, OR ULTRASONIC FREQUENCY, e.g. FOR PERFORMING MECHANICAL WORK IN GENERAL
    • B06B1/00—Methods or apparatus for generating mechanical vibrations of infrasonic, sonic, or ultrasonic frequency
    • B06B1/02—Methods or apparatus for generating mechanical vibrations of infrasonic, sonic, or ultrasonic frequency making use of electrical energy
    • B06B1/06—Methods or apparatus for generating mechanical vibrations of infrasonic, sonic, or ultrasonic frequency making use of electrical energy operating with piezoelectric effect or with electrostriction
    • B06B1/0644—Methods or apparatus for generating mechanical vibrations of infrasonic, sonic, or ultrasonic frequency making use of electrical energy operating with piezoelectric effect or with electrostriction using a single piezoelectric element
    • B06B1/0662—Methods or apparatus for generating mechanical vibrations of infrasonic, sonic, or ultrasonic frequency making use of electrical energy operating with piezoelectric effect or with electrostriction using a single piezoelectric element with an electrode on the sensitive surface
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23B—TURNING; BORING
    • B23B37/00—Boring by making use of ultrasonic energy
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23D—PLANING; SLOTTING; SHEARING; BROACHING; SAWING; FILING; SCRAPING; LIKE OPERATIONS FOR WORKING METAL BY REMOVING MATERIAL, NOT OTHERWISE PROVIDED FOR
    • B23D79/00—Methods, machines, or devices not covered elsewhere, for working metal by removal of material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B06—GENERATING OR TRANSMITTING MECHANICAL VIBRATIONS IN GENERAL
    • B06B—METHODS OR APPARATUS FOR GENERATING OR TRANSMITTING MECHANICAL VIBRATIONS OF INFRASONIC, SONIC, OR ULTRASONIC FREQUENCY, e.g. FOR PERFORMING MECHANICAL WORK IN GENERAL
    • B06B2201/00—Indexing scheme associated with B06B1/0207 for details covered by B06B1/0207 but not provided for in any of its subgroups
    • B06B2201/70—Specific application
    • B06B2201/73—Drilling
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23B—TURNING; BORING
    • B23B2215/00—Details of workpieces
    • B23B2215/04—Aircraft components
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23B—TURNING; BORING
    • B23B2270/00—Details of turning, boring or drilling machines, processes or tools not otherwise provided for
    • B23B2270/10—Use of ultrasound
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B29C65/08—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using ultrasonic vibrations
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/74—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by welding and severing, or by joining and severing, the severing being performed in the area to be joined, next to the area to be joined, in the joint area or next to the joint area
    • B29C65/743—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by welding and severing, or by joining and severing, the severing being performed in the area to be joined, next to the area to be joined, in the joint area or next to the joint area using the same tool for both joining and severing, said tool being monobloc or formed by several parts mounted together and forming a monobloc
    • B29C65/7443—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by welding and severing, or by joining and severing, the severing being performed in the area to be joined, next to the area to be joined, in the joint area or next to the joint area using the same tool for both joining and severing, said tool being monobloc or formed by several parts mounted together and forming a monobloc by means of ultrasonic vibrations
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2305/00—Condition, form or state of the layers or laminate
    • B32B2305/02—Cellular or porous
    • B32B2305/024—Honeycomb

Definitions

  • the invention relates to a honeycomb core ultrasonic cutting tool holder, belonging to the field of ultrasonic cutting of honeycomb core materials.
  • honeycomb core materials are widely used in the aerospace industry. Ultrasonic cutting of honeycomb core material has the advantages of high processing efficiency and good surface quality after processing, and has obvious processing advantages compared with the traditional high-speed milling method.
  • Ultrasonic cutting of honeycomb core materials requires dedicated ultrasonic cutting equipment.
  • it is also necessary to provide an ultrasonic cutting tool holder with large amplitude output performance.
  • ultrasonic cutting tool holder directly affects the processing quality of honeycomb core parts.
  • ultrasonic amplitude is small, such as ultrasonic assisted grinding, requires high-speed rotation of the grinding wheel, the speed is generally >3000r/min, the amplitude range is 2-10 microns, mainly under the aid of ultrasonic vibration shock, with the high speed of the grinding wheel Wipe-removed material; ultrasonic assisted drilling, bit speed range of 500 ⁇ 3000r / min, ultrasonic amplitude greater than 10 microns, high-speed cutting action of cutting edge to remove material under ultrasonic vibration assist; ultrasonic cutting process of honeycomb core In the middle, the straight edge knife does not rotate, the rotation speed of the disc cutter is low, generally less than 1500r/min, mainly relies on the ultrasonic vibration of the tool to remove the material, which requires the ultrasonic vibration system amplitude to be greater than 30 microns; therefore, the magnification of the ultrasonic system is required to be the traditional vibration.
  • the system vibration magnification is 5 to 10 times. Therefore, the design of the vibration system with
  • Ultrasonic-assisted grinding and ultrasonic drilling shank require less system amplitude, and often use a transducer to directly drive the first-quarter quarter-wave horn. The overall diameter and length of the vibration system are small.
  • the back end of the ultrasonic shank is connected to the machine tool using a standard taper shank, and the front end of the ultrasonic shank is connected to the ultrasonic tool. Because the type of the shank cavity only contains the transducer, the first horn is suspended outside the shank cavity, so that the ultrasonic shank has the characteristics of small volume, simple installation, convenient disassembly, and the like, and can not change the machine body.
  • the ultrasonic grinding and drilling functions are realized by a simple tool holder form.
  • ultrasonic cutting shanks often require the design of a dedicated multi-stage vibration system. Complex shank construction is also a design challenge for ultrasonic cutting shanks.
  • Ultrasonic-assisted grinding and drilling processing Due to the low ultrasonic power requirements, the heat generation between the transducer and its various mating surfaces is limited, and natural cooling is often used. There is no special design between the transducer and its mating surfaces. structure type. The power required for ultrasonic cutting is large, and the heat between the mating surfaces is severe. It is necessary to design a special internal cooling structure to ensure the stable operation of the system. The stable and reliable operation of the ultrasonic cutting tool holder and its internal cooling structure design are also the bottlenecks restricting the ultrasonic cutting application.
  • the honeycomb core ultrasonic cutting shank targets large amplitude ultrasonic output, a specially designed half-wavelength or full-wavelength vibration system is required, so the length and diameter of the vibration system are large.
  • the shank cavity The body will contain three parts: the transducer, the first horn and the second horn.
  • the overall size of the shank is large and the weight is heavy. If the tool holder is too long, it will reduce the effective stroke of the machine tool and affect the movement of the machine tool. If the weight of the tool holder is too large, it will exceed the bearing capacity of the machine tool spindle, which will bring hidden dangers to the safe operation of the machine tool.
  • the present invention proposes a A honeycomb core ultrasonic cutting tool that is suitable for use on a general purpose machine tool and has a quick change function.
  • a honeycomb core ultrasonic cutting shank comprising a shank, a slewing mechanism, a transducer, a first horn, a second horn, an ultrasonic cutting tool and an ultrasonic power transmission mechanism;
  • the shank includes a shank standard interface at an upper end and a shank housing at a lower end, and the outer wall of the shank housing has a stepped shaft shape, and includes a small shaft section, a middle shaft section and a large shaft section which are sequentially connected.
  • the small shaft segment is connected to the shank standard interface; the shank standard interface is provided with a central cooling hole extending into the small shaft segment;
  • the slewing mechanism includes an upper end cover located outside the small shaft section, a lower end cover located outside the large shaft section, and between the outer edge of the upper end cover and the outer edge of the lower end cover and passing through the bearing and the middle a fixing sleeve connected to the outer wall of the shaft section, the fixing sleeve is provided with a fixing sleeve cooling hole, and the inner wall of the fixing sleeve is provided with a fixing sleeve annular protrusion for pressing the outer ring of the bearing on the lower end cover;
  • the first horn has a cylindrical shape, and the lower end outer wall has a flange extending outwardly and connected to the inner wall of the large shaft section, and the upper end and the lower end of the flange are respectively provided with annular vibration isolation grooves, two The annular vibration isolating grooves are coaxially and staggered with the first-stage horns (ie, the two annular vibration isolation grooves are not unequal in radius, and are arranged in a reverse orientation of 180° to form a “labyrinth”
  • the vibration isolation structure avoids the influence of ultrasonic vibration on the precision of the machine tool spindle)
  • the flange is uniformly provided with a plurality of flange cooling holes
  • the axial position of the first horn is provided through the first-order variable amplitude a stepped hole of the rod
  • the stepped hole comprises a first-stage horn central cooling hole, a first-stage horn rod taper, a first-and second-order horn connecting screw hole and a
  • the transducer includes an inner cold pre-tightening bolt having a hollow structure, a rear cover plate and an annular ceramic sheet set, and the inner cold pre-tightening bolt is screwed to the first-stage horn central cooling hole, and through the a rear cover plate presses the annular ceramic piece group at a rear end of the first horn;
  • the second horn includes a second horn connecting screw shaft connected in sequence, a second horn aligning with a cone shaft, a second horn detaching shaft and an ultrasonic cutting tool connecting shaft, the second amplitude variator a rod connecting threaded shaft is threadedly connected with the first and second horn connecting threaded holes, and the outer wall of the second horn rod matching the tapered shaft is matched with the first and second horn positioning taper surfaces, the ultrasonic cutting a lower end of the tool connecting shaft has a threaded blind hole connecting the ultrasonic cutting tool, the thread blind hole includes a threaded blind hole thread segment and a taper hole at the thread blind hole opening, and the connecting portion of the ultrasonic cutting tool has a The threaded blind hole thread segment and the tapered hole matched the tool thread segment and the tool cone segment;
  • the honeycomb core ultrasonic cutting shank is arranged according to a displacement distribution curve: the flange and the first and second horn positioning cones are located at a node position of the displacement distribution curve; the cutting edge of the ultrasonic cutting tool is displaced a maximum displacement of the distribution curve; the setting of the vibration node and the displacement distribution curve of the honeycomb core ultrasonic cutting shank effectively reduces the ultrasonic vibration for the flange, the positioning taper of the first and second horns The effect is to maximize the cutting effect of the honeycomb core ultrasonic cutting shank, the shank structure is reasonable, and the layout is compact.
  • the outer wall of the ultrasonic cutting tool connecting shaft is designed according to the performance requirements of different ultrasonic cutting tools, and can be designed as a combination of a conical shape, a cylindrical shape, a conical cylindrical composite shape or an exponential, a step, a catenary line, a Bezier curve and the like. Contour surface.
  • the second horn can be replaced, the switching of different ultrasonic cutting systems can be realized, the manufacturing and use cost of the ultrasonic cutting shank can be reduced, and the interchangeability between different ultrasonic cutting shanks can be improved.
  • the ultrasonic power transmission mechanism includes a positive insulating ring sleeved on the small shaft segment, an upper end of the positive insulating ring is located below the upper end cover, and a lower end of the positive insulating ring is disposed at the small shaft a shoulder between the segment and the central shaft segment and an annular projection on a plane formed by the bearing inner ring, the annular projection pressing the bearing inner ring against the central shaft segment and the large a plurality of positive insulating ring cooling holes are disposed on the annular shoulders between the shaft segments, and the small shaft segments are provided with radial radial cooling holes communicating with the cooling holes of the positive insulating ring.
  • a positive conductive ring is sleeved on the positive insulating ring, a lower end of the positive conductive ring is located on the annular protrusion, and a positive insulating ring is provided on the positive insulating ring, and the small shaft segment is provided with a shank wiring hole communicating with the positive insulating ring wiring hole, wherein the positive conductive ring is provided with a wire, and the other end of the wire sequentially passes through the positive insulating ring wiring hole and the shank wiring hole and the The positive connection of the transducer, the upper end cap having an upper end cap thread a hollow cylindrical negative electrode connecting member is disposed in the threaded hole of the upper end cover, and an upper end of the hollow cylindrical negative electrode connecting piece is sleeved with a lower end opening of the fixed end negative electrode sleeve, and an upper end of the fixed end negative electrode sleeve is provided The fixed end negative electrode sleeve is pressed against the fixed end electrode adjusting spring of the upper end
  • the upper end cover and the small shaft segment, the upper end cover and the upper end of the positive insulating ring, and the lower end cover and the large shaft segment have a gap therebetween.
  • the fixed end electrode adjusting spring, the positive electrode adjusting spring, the positive electrode brush adjusting spring, the fixed end negative electrode sleeve and the hollow cylindrical negative electrode connecting piece are coupled and matched to realize ultrasonic power supply positive electrode and negative electrode and ultrasonic The cutting shank is reliably connected.
  • the bearing sleeve is coupled to the shank housing by the bearing, and the shank housing is driven by the machine tool spindle to drive the positive conductive ring to rotate; the upper cover and the fixed sleeve The lower cover plate and the ultrasonic power transmission mechanism (except the positive insulating ring and the positive conductive ring) are not rotated, and the positive carbon brush is kept under the action of the positive electrode brush adjusting spring.
  • the honeycomb core ultrasonic cutting tool holder has better integration and can be effective
  • the size and quality of the honeycomb core ultrasonic cutting tool holder are reduced, the space of the spindle end face is avoided, and the size interference is facilitated, and the automatic tool changing is facilitated.
  • the positive and negative connectors also function to adaptively contact the state and transmit torque while transmitting electrical energy, and ensure that the ultrasonic power transmission mechanism (except the positive insulating ring and the positive conductive ring) does not rotate.
  • the ultrasonic power transmission mechanism can be designed to be quickly replaced without increasing the level of automation for disassembling the power transmission mechanism.
  • Cooling gas enters the shank housing through the center cooling hole of the shank, and the inside of the inner cooling pre-tightening bolt can pass through a cooling gas, and when the second horn is replaced, the cooling gas enters the stepped hole,
  • the first and second horn connecting rod threaded holes and the first and second horn positioning cones serve to clean, improve the matching precision of the cone surface, and improve the energy transfer efficiency of the ultrasonic cutting;
  • the first horn and the first horn After the secondary horn is assembled, the stepped hole is sealed, and cooling air flows out from the flange cooling hole to the connection of the ultrasonic cutting tool connecting shaft and the ultrasonic cutting tool, While the transducer in the shank housing is tropically traversing, the connection between the ultrasonic cutting tool connecting shaft and the ultrasonic cutting tool is cooled; another part of cooling air passes through the shank diameter Cooling holes to the cooling holes and the positive insulating ring, through the passage between the fixing sleeve and the positive insulating ring, flowing
  • the lower end of the inner wall of the large shaft section is provided with an annular sundeck for accommodating the flange, and the honeycomb core ultrasonic cutting shank further comprises a flange end cover, the flange end cover is said by a flange fastening bolt A flange is pressed against the annular table, the axis of the flange cooling hole being directed to the junction of the ultrasonic cutting tool connecting shaft and the ultrasonic cutting tool.
  • a connecting surface of the ultrasonic cutting system and the shank is disposed at the flange; the first horn is integrally disposed in the shank housing; and the second horn passes the first horn a rod is coupled to the shank housing, the second horn is integrally disposed outside the shank housing, and the shank housing only includes the structural design of the first horn, effectively reducing
  • the outer dimensions and weight of the honeycomb core ultrasonic cutting tool holder solve the applicability of the honeycomb core ultrasonic cutting tool holder on different machine tools.
  • the second horn removal shaft is provided with a wrench groove, and the outer wall of the ultrasonic cutting tool connecting shaft is a conical, cylindrical, conical cylindrical composite shape or an index, a step, a catenary line, a Bezier curve and the like.
  • the outer contour surface formed by the composite is a conical, cylindrical, conical cylindrical composite shape or an index, a step, a catenary line, a Bezier curve and the like.
  • the ratio of the diameter of the primary horn to the secondary horn is greater than or equal to 2, that is, the diameter ratio of the diameter of the primary horn to the front end of the secondary horn is greater than or equal to 2.
  • the total length of the transducer and the primary horn (the rear end of the transducer to the front end of the primary horn) is an integer multiple of a quarter wavelength
  • the second amplitude The total length of the rod and the ultrasonic cutting tool (the secondary end of the secondary horn to the front end of the ultrasonic cutting tool) is a quarter wavelength plus an integer multiple of a half wavelength.
  • the second horn connecting threaded shaft and the one or two horn connecting thread holes are connected by a fine thread, and the first and second horn positioning cones have a taper angle greater than 0° and less than 90°.
  • a short tapered surface the threaded blind hole thread segment and the tool thread segment are connected by a fine thread, the tapered hole being a short tapered surface having a cone angle greater than 0° and less than 90°.
  • An axis of the fixing sleeve cooling hole is located above the positive conductive ring, and an axis of the positive insulating ring cooling hole is located below the positive conductive ring.
  • the shank standard interface is connected to the machine tool spindle through a shank pull pin, and the shank pull pin is provided with a cold hole in the shank puller communicating with the central cooling hole of the shank, the standard interface of the shank and the shank
  • the shank pull pin is threaded.
  • the outer wall of the hollow cylindrical negative electrode connecting member is provided with a limiting flange that is in contact with the upper surface of the upper end cover;
  • the upper end of the hollow cylindrical negative electrode connector has a tapered surface, and the lower end opening of the fixed end negative electrode sleeve has an open annular groove, and the groove bottom of the open annular groove matches the upper end of the hollow cylindrical negative electrode connector
  • the inner wall of the open annular groove is matched with the outer wall of the hollow cylindrical negative electrode connector
  • the hollow cylindrical electrode insulation limiting member is a split structure, including a limiting ring and a limiting member body, and a lower surface of the limiting ring and an upper portion of the inner wall of the limiting member body constitute the limiting annular groove ;
  • the upper end of the positive electrode sleeve has a truncated cone shape.
  • the upper end of the fixed end electrode adjusting spring is fixedly engaged with the end surface of the machine tool spindle (not shown), and is connected with the negative pole of the ultrasonic power source, and the lower end is connected with the negative pole sleeve of the fixed end;
  • the cylinder is a hollow cylindrical conductive structure, and a lower end is connected to the hollow cylindrical negative electrode connecting member, and the hollow cylindrical negative electrode connecting member is connected to the upper cover plate.
  • the fixed end negative electrode sleeve Under the spring force of the end electrode adjusting spring, the fixed end negative electrode sleeve is ensured to be in reliable contact with the hollow cylindrical negative electrode connecting member, and the inner wall of the open annular groove is matched with the outer wall of the hollow cylindrical negative electrode connecting member
  • the taper contact between the electrodes realizes the automatic adjustment and centering function of the electrode, and the cylindrical surface contact can reliably overcome the torque generated by the rotation during use, ensuring the safe and reliable transmission of electric energy; during the working process, the ultrasonic energy a negative electrode flowing through the fixed end electrode adjusting spring, the fixed end negative electrode sleeve, the hollow cylindrical negative electrode connecting piece, the
  • the cover plate, the fixing sleeve, the bearing, the shank housing, the first horn are electrically connected, and are electrically connected to the negative electrode of the annular ceramic piece group through the first horn, Form a negative circuit.
  • the positive-circuit circuit portion the fixed-end insulating member is a cylindrical conductive structure as a whole, the upper end is tightly coupled with the inner bottom of the fixed-end negative-diameter sleeve, and the outer wall is fastened and coupled with the inner wall of the fixed-end negative sleeve.
  • the other end surface is a cylindrical counterbore structure, and the fixed end positive electrode is embedded, and the fixed end insulating member functions to insulate the fixed end negative electrode sleeve and the fixed end positive electrode;
  • the side is connected to the positive electrode of the ultrasonic power source, and the lower side is in contact with the positive electrode sleeve, and then the positive electrode is adjusted by the positive electrode brush, the positive electrode brush, the positive electrode conductive ring and the wire and the positive electrode of the transducer (ie, the annular ceramic piece
  • the positive electrode of the group is turned on.
  • the hollow cylindrical electrode insulation limiting member is disposed between the positive electrode sleeve and the hollow cylindrical negative electrode connecting member, and the lower portion of the inner wall in the hollow cylindrical electrode insulating limiting member and the outer wall of the positive electrode sleeve Cooperating, the limiting annular groove is radially matched with the positive sleeve flange, and the axial dimension of the limiting annular groove is larger than the thickness of the positive sleeve flange, so that the positive sleeve is Insulation limit in the radial direction, a certain amount of telescopic adjustment in the axial direction.
  • a positive adjustment spring that presses the upper end of the positive electrode sleeve against the fixed terminal positive electrode is further disposed between the lower end of the positive electrode sleeve and the lower end inner wall of the hollow cylindrical electrode insulation limiting member.
  • the positive electrode sleeve is axially movable under the action of the elastic force of the positive electrode adjusting spring to ensure reliable contact with the fixed terminal positive electrode; during the rotation of the honeycomb core ultrasonic cutting tool holder, the positive electrode is electrically
  • the brush is fixed, and the positive conductive ring rotates with the honeycomb core ultrasonic cutting shank, and the positive electrode and the positive conductive ring maintain contact with each other during rotation under the action of the positive electrode adjusting spring To achieve reliable transmission of electrical energy.
  • honeycomb core ultrasonic cutting tool holder can be used as a separate component to facilitate connection and disassembly of the overall tool holder and the machine tool spindle.
  • the ultrasonic cutting tool includes a cutter body
  • One end of the cutter body has the cutter cone segment (to achieve a coaxiality between the cutter and the threaded blind hole thread segment), and the cutter cone segment is provided with the cutter thread segment connected to the threaded blind hole thread segment.
  • the other end of the cutter body has a groove, the groove includes a tapered groove bottom, a cylindrical hole and a frustum-shaped hole at the groove notch (to reduce the outer wall of the ultrasonic cutting tool and the honeycomb core material) Friction), an arcuate transition between the tapered groove bottom and the cylindrical hole (to avoid stress concentration under ultrasonic action), the small end of the frustum-shaped hole is connected to the cylindrical hole ;
  • the frustum-shaped hole and the outer wall of the cutter body away from one end of the cutter cone form a horn-shaped cutting edge, and the cutter body has a frustum shape away from an outer wall of one end of the cutter cone, and the cutter body is away from the cutter a small end of the outer wall of one end of the tapered section is located between the two ends of the cylindrical hole;
  • a cutter groove is disposed on an outer wall of the cutter body between the cutter cone segment and the tapered groove bottom, and at least one end of the cylindrical hole adjacent to the tapered groove bottom is provided with the cutter a tapping port through which the outer wall of the main body passes, and an inner wall of the hole portion of the cylindrical hole adjacent to the frustum-shaped hole is provided with at least one chute penetrating from the outer wall of the cutter body.
  • the diameter of the notch of the tapered groove bottom is smaller than the diameter of the cylindrical hole.
  • the ultrasonic cutting tool is coaxial with the thread blind hole thread segment.
  • the threaded blind bore thread segments transmit axial high frequency vibrations to the ultrasonic cutting tool.
  • An inner wall of the cylindrical hole is provided with a chip flute for discharging chips to the chip discharge port, the chip flute being parallel to an axis of the ultrasonic cutting tool or around the axis of the ultrasonic cutting tool by the frustum shape
  • the hole spirals upward toward the chip exit.
  • the chip flutes are selected from a grooveless structure, a flat structure and a spiral structure.
  • the length between the cutter cone segment and the large end of the frustum-shaped hole is 0.25 to 0.5 times of the propagation wavelength of the ultrasonic cutting tool material, which is too short to meet the ultrasonic vibration requirement, and too long cannot guarantee the The axial stiffness of the ultrasonic cutting tool.
  • the flared cutting edge has a wedge angle of 2 to 10 degrees.
  • the chute is inclined toward the cutter cone, and the number of the chutes is three or more, and the chutes are parallel to each other and are equally spaced along the axis of the ultrasonic cutting tool, the chute
  • the spacing between the spacing is less than the wavelength of the acoustic wave propagating in the ultrasonic cutting tool material, and the function of the chute is to convert the longitudinal vibration transmitted from the threaded blind hole thread segment into a superposition of torsional vibration and longitudinal vibration. It is transmitted to the horn-shaped cutting edge, which facilitates the removal of material during cutting.
  • the ultrasonic cutting tool is uniformly distributed with two or more of the fluffing ports in the circumferential direction, and the fluffing opening is parallel or inclined to the rectangular or long axis with the long side parallel to the axis of the ultrasonic cutting tool
  • the elliptical opening of the axis of the ultrasonic cutting tool can also be other shapes that facilitate chip discharge.
  • the wrench slot is a rectangular wrench slot and its plane is parallel to the axis of the ultrasonic cutting tool.
  • the material of the ultrasonic cutting tool is high speed steel or cemented carbide to transmit high frequency axial vibration.
  • the present invention proposes a honeycomb core ultrasonic cutting tool holder having a large amplitude output capability while considering the interchangeability requirement between different vibration systems, and solving the ultrasonic cutting tool holder on a general machine tool. Applicability problems improve the automation level of ultrasonic cutting;
  • the introduction of ultrasonic vibration reduces the cutting force of the honeycomb core cutting process, effectively suppresses the crushing deformation damage of the honeycomb core, and ensures the processing quality and processing precision;
  • Ultrasonic vibration can effectively reduce the wear of ultrasonic cutting tools and reduce the processing cost
  • Ultrasonic vibration has a good anti-friction effect, which can ensure that the ultrasonic cutting tool is processed and the chip automatically slides out of the ultrasonic cutting tool in the center of the lifting process. It does not accumulate in the groove, and does not need to be shut down to clean the cutting to ensure the continuity of processing. The processing efficiency is improved.
  • the honeycomb core chips that are not discharged in time in the groove can be discharged through the chip discharge slot through the chip flute during the processing, thereby further solving the problem of difficult chip removal in the honeycomb core cutting process.
  • the present invention can be widely applied in the field of ultrasonic machining of honeycomb core materials and the like.
  • Fig. 1 is a cross-sectional view showing a honeycomb core ultrasonic cutting shank according to a first embodiment of the present invention and a displacement distribution curve corresponding thereto.
  • Figure 2 is a cross-sectional view showing a honeycomb core ultrasonic cutting shank (except for a secondary horn and an ultrasonic cutting tool) in Embodiment 1 of the present invention.
  • Fig. 3 is an enlarged schematic view showing a portion A of Fig. 2;
  • Figure 4 is a cross-sectional view showing an ultrasonic power transmission mechanism in Embodiment 1 of the present invention.
  • Figure 5 is a cross-sectional view of a secondary horn equipped with a large wafer cutter in Embodiment 1 of the present invention.
  • Figure 6 is a cross-sectional view showing a secondary horn equipped with a straight blade in the first embodiment of the present invention.
  • Figure 7 is a cross-sectional view of a secondary horn equipped with a small circular blade cutter in Embodiment 1 of the present invention.
  • Figure 8 is a cross-sectional view of a secondary horn equipped with an ultrasonic cutting tool in Embodiment 2 of the present invention.
  • Figure 9 is a schematic view showing the structure of an ultrasonic cutting tool in Embodiment 2 of the present invention.
  • Figure 10 is a cross-sectional view showing an ultrasonic cutting tool in Embodiment 2 of the present invention.
  • Figure 11 is a cross-sectional view showing an ultrasonic cutting tool in Embodiment 3 of the present invention.
  • Figure 12 is a cross-sectional view showing an ultrasonic cutting tool in Embodiment 4 of the present invention.
  • Figure 13 is a circular arc feature of a conventional cutting tool after machining a honeycomb core.
  • Fig. 14 is a view showing the arc characteristics of the ultrasonic cutting tool after the honeycomb core is processed in the second embodiment of the present invention.
  • a honeycomb core ultrasonic cutting tool holder includes a tool holder, a slewing mechanism, a transducer, a first horn, a second horn, an ultrasonic cutting tool 1 and an ultrasonic power transmission mechanism. ;
  • the shank includes a shank standard interface 2 at an upper end and a shank housing at a lower end, the outer wall of the shank housing is stepped shaft-shaped, including a small shaft section 3, a middle shaft section 4 and a large a shaft section 5, the small shaft section 3 is connected to the shank standard interface 2; the shank standard interface 2 is provided with a shank central cooling hole 6 extending into the small shaft section 3;
  • the slewing mechanism includes an upper end cover 7 located outside the small shaft section 3, a lower end cover 8 located outside the large shaft section 5 and between the outer edge of the upper end cover 7 and the outer edge of the lower end cover 8 and a fixing sleeve 10 connected to the outer wall of the middle shaft section 4 by a bearing 9, the fixing sleeve 10 is provided with a fixing sleeve cooling hole 11, and the inner wall of the fixing sleeve 10 is provided with the outer ring of the bearing 9 pressed a fixing sleeve annular protrusion 12 on the lower end cover 8;
  • the first horn has a cylindrical shape, and the lower end outer wall has a flange 13 extending outwardly and connected to the inner wall of the large shaft section 5.
  • the upper end and the lower end of the flange 13 are respectively provided with annular vibration isolation.
  • a groove 14 two of the annular vibration isolating grooves 14 are coaxially and alternately arranged with the first-stage horn, and the flange 13 is evenly distributed with a plurality of flange cooling holes 15 , the first-order variable amplitude
  • the axial position of the rod is provided with a stepped hole penetrating the first horn, the stepped hole comprises a first horn central cooling hole 16 connected in sequence, a first horn taper hole 17, a first and second variator
  • the rod is connected with the threaded hole 18 and the first and second horn positioning taper surface 19;
  • the transducer comprises an inner cold pre-tightening bolt 20 having a hollow structure, a rear cover plate 21 and an annular ceramic sheet set 22, and the inner cold pre-tightening bolt 20 is connected to the primary horn central cooling hole thread 16 And pressing the annular ceramic sheet group 22 to the rear end of the first horn by the rear cover 21;
  • the secondary horn includes a secondary horn connecting threaded shaft 23 connected in sequence, a secondary horn engaging a tapered shaft 24, a secondary horn removing shaft 25 and an ultrasonic cutting tool connecting shaft 26, a second horn connecting threaded shaft 23 is threadedly connected with the first and second horn connecting threaded holes 18, the second horn is matched with the outer wall of the tapered shaft 24 and the first and second horn positioning cones
  • the face 19 is matched, and the lower end of the ultrasonic cutting tool connecting shaft 26 has a threaded blind hole connecting the ultrasonic cutting tool 1, the thread blind hole including a threaded blind hole thread segment 27 and a cone located at the thread blind hole opening a hole 28, the connecting portion of the ultrasonic cutting tool 1 has a tool thread segment and a tool cone segment that match the threaded blind hole thread segment 27 and the tapered hole 28;
  • the ultrasonic power transmission mechanism includes a positive insulating ring 29 sleeved on the small shaft segment 3, an upper end of the positive insulating ring 29 is located below the upper end cover 7, and a lower end of the positive insulating ring 29 is provided.
  • annular protrusion 30 On a plane formed between the small shaft section 3 and the middle shaft section 4 and a plane formed by the inner ring of the bearing 9, the annular protrusion 30 will inner ring of the bearing 9 Pressed on the shoulder between the middle shaft section 4 and the large shaft section 5, the annular protrusion 30 is provided with a plurality of positive insulation ring cooling holes 31, and the small shaft section 3 is provided with The positive electrode insulating ring 29 is connected to the shank radial cooling hole 32, the positive electrode insulating ring 29 is sleeved with a positive electrode conductive ring 33, and the lower end of the positive electrode conductive ring 33 is located on the annular protrusion 30.
  • a positive insulating ring 30 is disposed on the positive insulating ring 30, and the small shaft 3 is provided with a shank connecting hole 35 communicating with the positive insulating ring connecting hole 34.
  • the positive conductive ring 33 is disposed on the positive conductive ring 33.
  • the upper end cover 7 has an upper end cover threaded hole, and the upper end cover threaded hole is provided with a hollow cylindrical negative electrode connecting member 37, and the upper end of the hollow cylindrical negative electrode connecting member 37 and the fixed end negative electrode sleeve 38 are The lower end opening is sleeved, and the upper end of the fixed end negative electrode sleeve 38 is provided with a fixed end electrode adjusting spring 39 for pressing the fixed end negative electrode sleeve 38 to the upper end of the hollow cylindrical negative electrode connecting member 37, the fixing
  • the inner bottom of the end negative sleeve 38 is provided with a fixed end insulating member 40.
  • the fixed end insulating member 40 has a fixed end positive electrode 41 embedded therein, and the hollow cylindrical negative connecting member 37 is sleeved therein.
  • a hollow cylindrical electrode insulation limiting member the upper portion of the inner wall of the hollow cylindrical electrode insulation limiting member is provided with a limiting annular groove 42, and the hollow cylindrical electrode insulating limiting member is provided with a positive electrode sleeve 43 for the positive electrode
  • An outer wall of the sleeve 43 is provided to radially match the positive annular groove 42 with a positive sleeve flange 44.
  • the positive sleeve 43 passes through the positive sleeve flange 44 along the limiting annular groove 42.
  • the positive sleeve 43 is provided There is a positive carbon brush 45 extending from the lower end opening of the positive electrode sleeve 43 and the lower end of the hollow cylindrical electrode insulation limiting member, and the positive electrode sleeve 43 is further provided with the positive carbon brush 45.
  • a positive electrode brush adjusting spring 46 pressed on the positive conductive ring 33, and a positive sleeve is disposed between a lower end of the positive electrode sleeve 43 and a lower end inner wall of the hollow cylindrical electrode insulating stopper The upper end of the 43 is pressed against the fixed end positive electrode 41 of the positive adjustment spring 47;
  • the upper end cover 7 and the small shaft section 3, the upper end cover 7 and the upper end of the positive electrode insulating ring 29, and the lower end cover 8 and the large shaft section 5 have a gap therebetween.
  • the lower end of the inner wall of the large shaft section 5 is provided with an annular sunroof for accommodating the flange 13, and the honeycomb core ultrasonic cutting shank further comprises a flange end cover 48, which is fastened by a flange.
  • a bolt presses the flange 13 against the annular table, the axis of the flange cooling hole 15 being directed to the junction of the ultrasonic cutting tool connecting shaft and the ultrasonic cutting tool.
  • An axis of the fixing sleeve cooling hole 11 is located above the positive conductive ring 33, and an axis of the positive insulating ring cooling hole 31 is located below the positive conductive ring 33.
  • the second horn removing shaft 25 is provided with a wrench groove 49, and the outer wall of the ultrasonic cutting tool connecting shaft 26 is a conical, cylindrical, conical cylindrical composite shape (as shown in FIG. 7) or an index (as shown in the figure). 6)), step (as shown in Figure 5), catenary, Bezier curve and other functions combined to form the outer contour surface.
  • the cutting edge of the ultrasonic cutting tool 1 shown is a large disc cutter (as shown in Fig. 5), a straight edge sharp knife (shown in Fig. 6) or a small disc cutter (shown in Fig. 7).
  • the ratio of the diameter of the primary horn to the secondary horn is greater than or equal to 2, that is, the diameter ratio of the diameter of the primary horn to the front end of the secondary horn is greater than or equal to 2.
  • the total length of the transducer and the primary horn is an integer multiple of a quarter wavelength
  • the total length of the secondary horn and the ultrasonic cutting tool 1 is a quarter wavelength plus An integer multiple of the upper half of the wavelength.
  • the second horn connecting threaded shaft 23 and the one or two horn connecting threaded holes 18 are connected by a fine thread, and the first and second horn positioning tapers 19 have a taper angle greater than 0° and less than A short tapered surface of 90°; the threaded blind hole thread segment 27 and the tool thread segment are connected by a fine thread, and the tapered hole 28 is a short tapered surface having a taper angle greater than 0° and less than 90°.
  • the shank standard interface 2 is connected to the machine tool spindle through a shank pull 50, and the shank pull 50 is provided with a shank inner cold hole 51 communicating with the shank central cooling hole 6
  • the shank standard interface 2 is threadedly coupled to the shank puller 50.
  • the outer wall of the hollow cylindrical negative electrode connecting member is provided with a limiting flange that is in contact with the upper surface of the upper end cover;
  • the upper end of the hollow cylindrical negative electrode connector 37 has a tapered surface, and the lower end opening of the fixed end negative electrode sleeve 38 has an open annular groove, and the groove bottom of the open annular groove and the hollow cylindrical negative electrode connector 37 The upper ends are matched, and the inner wall of the open annular groove is matched with the outer wall of the hollow cylindrical negative electrode connector 37;
  • the hollow cylindrical electrode insulation limiting member is a split structure, and includes a limiting ring 52 and a limiting member main body 53.
  • the lower surface of the limiting ring 52 and the upper portion of the inner wall of the limiting member main body 53 constitute the Limit annular groove 42;
  • the upper end of the positive electrode sleeve 43 has a truncated cone shape.
  • a seal ring 54 is disposed in a gap between the lower end cap 8 and the large shaft segment 5.
  • a honeycomb core ultrasonic cutting shank is distinguished from a honeycomb core ultrasonic cutting shank according to Embodiment 1 in that the ultrasonic cutting tool 1 includes a cutter body;
  • One end of the cutter body has a cutter cone section 55, and the cutter cone section 55 is provided with the cutter thread segment 56 connected to the threaded blind hole thread segment, and the other end of the cutter body has a groove,
  • the groove includes a tapered groove bottom 57, a cylindrical hole 58 and a frustum-shaped hole 59 at the groove notch, and a circular arc transition section is arranged between the tapered groove bottom 57 and the cylindrical hole 58. 60, the small end of the frustum-shaped hole 59 is in communication with the cylindrical hole 58;
  • the frustum-shaped hole 59 and the outer wall 65 of the cutter body away from one end of the cutter cone form a horn-shaped cutting edge, and the cutter body is tapered away from the outer wall 65 at one end of the cutter cone, and the cutter body is away from the cutter body a small end of the outer wall 65 at one end of the cutter cone is located between the two ends of the cylindrical hole;
  • a cutter groove 61 is disposed on an outer wall of the cutter body between the cutter cone section 55 and the tapered groove bottom 57, and at least one end of the cylindrical hole 58 adjacent to the tapered groove bottom 57 is provided with at least one end of the cylindrical hole 58 near the tapered groove bottom 57.
  • a discharge port 62 penetrating from the outer wall of the cutter body, and an inner wall of the hole portion of the cylindrical hole 58 adjacent to the frustum-shaped hole 59 is provided with at least one chute 63 penetrating from the outer wall of the cutter body.
  • the inner wall of the cylindrical hole 58 is provided with a chip flute 64 for discharging chips to the tapping port 62, and the chip flute 64 is wound by the frustum-shaped hole 59 around the axis of the ultrasonic cutting tool 1
  • the swarf opening 62 spirals upward.
  • the length between the tool cone section 55 and the large end of the frustum-shaped hole 59 is 0.25 to 0.5 times the wavelength of the sound wave propagation of the material of the ultrasonic cutting tool 1.
  • the frustum-shaped cutting edge formed by the frustum-shaped hole 59 has a cutting edge wedge angle of 2 to 10°.
  • the inclined groove 63 is inclined toward the cutter cone segment 55, and the number of the oblique grooves 63 is three, and the inclined grooves 63 are parallel to each other and are arranged at equal intervals along the axis of the ultrasonic cutting tool 1, the inclined The spacing between the slots 63 is less than the wavelength at which the acoustic waves propagate in the material of the ultrasonic cutting tool 1.
  • the ultrasonic cutting tool 1 is evenly distributed with two of the flutes 62 in the circumferential direction, and the flute 62 is a rectangular opening having a long side parallel to the axis of the ultrasonic cutting tool 1.
  • the wrench groove 61 is a rectangular wrench groove and its plane is parallel to the axis of the ultrasonic cutting tool 1 .
  • the material of the ultrasonic cutting tool 1 is high speed steel or cemented carbide.
  • the tool cone section 55 is a tapered surface.
  • This embodiment is for high-density honeycomb core processing, and the spiral direction of the chip flute 64 is opposite to the direction in which the ultrasonic cutting tool 1 rotates. Since the hardness of the honeycomb core is high and the processing deformation is small, the discharge direction of the chip core after each cutting is opposite to the rotation direction of the ultrasonic cutting tool 1, and rises along the chip flute 64, and the chip core generated by the next cutting will be The top is discharged to the fluff 62, so that it reciprocates to achieve automatic chip evacuation.
  • a honeycomb core ultrasonic cutting shank is distinguished from a honeycomb core ultrasonic cutting shank of the second embodiment in that the ultrasonic cutting tool 1 has no chip flutes.
  • the embodiment is used for a low-density honeycomb core. Since the processing deformation of the medium-low density honeycomb core is large, the friction between the inner wall of the groove and the chip of the honeycomb core is small, and under the action of ultrasonic vibration and ultrasonic reduction, when After one cut is completed, the chip core will be detached from the groove, thereby achieving automatic chip evacuation.
  • FIG. 13 and FIG. 14 are respectively the circular arc features of the conventional cutting tool and the ultrasonic cutting tool 1 of the present invention after cutting the honeycomb core, and the visible improvement of the processing quality of the honeycomb core arc feature can be seen in comparison.
  • a honeycomb core ultrasonic cutting shank is distinguished from the honeycomb core ultrasonic cutting shank of the second embodiment by the chip flute 64 and the axis of the ultrasonic cutting tool 1. parallel.
  • the embodiment is used for a medium density honeycomb core, and the chip flute 64 is parallel to the axis of the ultrasonic cutting tool 1.
  • the chips in the chip flute 64 are separated by a small portion under the action of rotation. And discharging along the chip flute 64 to the chip discharge port 62, and the residual chips that are not shredded are smaller than the diameter of the groove, and the groove is removed from the groove under the action of ultrasonic vibration and ultrasonic vibration reduction. Disengaged in the middle to achieve automatic chip evacuation.

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Abstract

公开了一种蜂窝芯超声切削刀柄。该蜂窝芯超声切削刀柄包括刀柄，回转机构，换能器、一级变幅杆、二级变幅杆、超声切削刀具和超声电能传输机构。该蜂窝芯超声切削刀柄具有大振幅输出能力，考虑不同振动系统间的互换性要求，解决了超声切削刀柄在通用机床上的适用性难题，提高了超声切削的自动化水平。

Description

一种蜂窝芯超声切削刀柄 技术领域
本发明涉及一种蜂窝芯超声切削刀柄，属于蜂窝芯材料超声切削加工领域。
背景技术
蜂窝芯材料作为一种轻质高强的填充材料，被广泛应用于航空航天领域。蜂窝芯材料超声切削具有加工效率高、加工后表面质量好等优点，相对传统的高速铣削方法具有明显的加工优势。
蜂窝芯材料超声切削需要专用的超声切削装备。为了加工出不同形状要求的蜂窝芯零件，除了需要多轴联动的蜂窝芯超声切削机床外还要配备具有大振幅输出性能的超声切削刀柄才能实现。超声切削刀柄作为超声切削加工的关键环节，其性能好坏直接影响到蜂窝芯零件的加工质量。
传统的超声辅助加工，超声振幅较小，如超声辅助磨削，要求砂轮高速回转，转速一般＞3000r/min，振幅范围在2～10微米，主要在超声振动冲击辅助下，以砂轮的高速划擦去除材料；超声辅助钻削，钻头转速范围在500～3000r/min，要求超声振幅大于10微米，在超声振动辅助作用下以切削刃的高速切削作用去除材料；而蜂窝芯的超声切削加工过程中，直刃尖刀不回转，圆盘刀转速低，一般小于1500r/min，主要靠刀具的超声振动去除材料，这就要求超声振动系统振幅大于30微米；因此要求超声系统的放大倍数要是传统振动系统振动放大倍数的5～10倍。因此大振幅放大倍数的振动系统设计是超声切削刀柄难点。
超声辅助磨削和超声钻削刀柄对于系统振幅需求较小，往往采用换能器直接带动一级四分之一波长变幅杆的方案，振动系统整体直径和长度较小。超声刀柄后端采用标准锥柄与机床连接，超声刀柄前端与超声刀具连接。因为该类刀柄腔体内仅含换能器，一级变幅杆悬出在刀柄腔体外，使得这种超声刀柄具有体积小、安装简单，拆卸方便等特点，可以在不改变机床本体结构的情况下，通过简单的刀柄形式实现超声磨削和钻削功能。与超声磨削和钻削刀柄不同，超声切削刀柄往往需要设计专用的多级振动系统实现，复杂的刀柄结构也是超声切削刀柄的设计难题。
超声辅助磨削和钻削加工由于超声功率需求较低，换能器及其各个配合面之间的发热有限，往往采用自然冷却的方式，换能器及其各个配合面之间不用设计特殊的结构形式。而超声切削所需的功率大，各个配合面之间发热严重，需要设计特殊的内冷结构才能保证系统的稳定工作。超声切削刀柄的稳定可靠工作及其内冷结构设计也是制约超声切削应用的瓶颈。
由于蜂窝芯超声切削刀柄以大振幅超声输出为目标，需要采用特殊设计的半波长或整波 长振动系统，因此振动系统的长度和直径大，如果沿用传统的超声刀柄设计思路，刀柄腔体将包含换能器、一级变幅杆和二级变幅杆三部分，刀柄整体尺寸大和重量沉。刀柄过长会减小机床的有效行程，影响机床的动作；刀柄重量过大会超出机床主轴的承载能力，给机床的安全运行带来隐患。
同时由于不同的超声切削刀具对应不同的超声切削刀柄，超声切削刀具种类繁多，需要设计和制造众多与之相匹配的超声切削刀柄。同时由于现有的蜂窝芯超声切削刀柄设计为一体化结构，在蜂窝芯零件的加工过程中，为了更换不同的超声切削刀具，往往需要更换整个超声切削刀柄。这种换刀形式需要配合特殊的刀柄库和换刀系统才能实现，机床结构设计复杂。同时由于抓取和存放整个超声切削刀柄的换刀工艺准备时间长，且存放这些刀柄所占用的空间大，限制了蜂窝芯零件超声切削自动化效率的提高。同时由于不同的超声刀具均需要配备与之相对应的一整套超声切削刀柄，使得超声切削的设备成本较高，不利于超声切削工艺的推广。
发明内容
为了解决超声切削刀柄在通用机床上的可用性、适用性和互换性难题，降低超声系列化切削刀柄的制造和使用成本，提高不同超声切削系统间的换刀效率，本发明提出了一种可在通用机床上适用的且具有快换功能的蜂窝芯超声切削刀柄。
本发明采用的技术手段如下：
一种蜂窝芯超声切削刀柄，包括刀柄，回转机构，换能器、一级变幅杆、二级变幅杆、超声切削刀具和超声电能传输机构；
所述刀柄包括位于上端的刀柄标准接口和位于下端的刀柄壳体，所述刀柄壳体的外壁呈阶梯轴状，包括依次连接的小轴段、中轴段和大轴段，所述小轴段与所述刀柄标准接口连接；所述刀柄标准接口上设有延伸至所述小轴段内的刀柄中心冷却孔；
所述回转机构包括位于所述小轴段外侧的上端盖，位于所述大轴段外侧的下端盖和位于所述上端盖外沿和所述下端盖外沿之间且通过轴承与所述中轴段外壁连接的固定套，所述固定套上设有固定套冷却孔，所述固定套内壁设有将所述轴承外圈压在所述下端盖上的固定套环形凸起；
所述一级变幅杆呈圆柱状，其下端外壁具有向外延伸且与所述大轴段内壁连接的法兰盘，所述法兰盘的上端和下端分别设有环形隔振槽，两个所述环形隔振槽与所述一级变幅杆同轴且交错设置(即两个所述环形隔振槽所处的半径不相等，且呈180°反向布置，形成“迷宫式”隔振结构，避免超声振动对于机床主轴精度的影响)，所述法兰盘上均布有多个法兰冷却孔，所述一级变幅杆的轴线位置设有贯通所述一级变幅杆的阶梯孔，所述阶梯孔包括依次连接的一级变幅杆中心冷却孔、一级变幅杆锥孔、一二级变幅杆连接螺纹孔和一二级变幅杆定 位锥面；
所述换能器包括具有中空结构的内冷预紧螺栓，后盖板和环形陶瓷片组，所述内冷预紧螺栓与所述一级变幅杆中心冷却孔螺纹连接，且通过所述后盖板将所述环形陶瓷片组压在所述一级变幅杆后端；
所述二级变幅杆包括依次连接的二级变幅杆连接螺纹轴，二级变幅杆配合锥面轴，二级变幅杆拆卸轴和超声切削刀具连接轴，所述二级变幅杆连接螺纹轴与所述一二级变幅杆连接螺纹孔螺纹连接，所述二级变幅杆配合锥面轴的外壁与所述一二级变幅杆定位锥面相匹配，所述超声切削刀具连接轴的下端具有连接所述超声切削刀具的螺纹盲孔，所述螺纹盲孔包括螺纹盲孔螺纹段和位于所述螺纹盲孔开口的锥孔，所述超声切削刀具的连接部具有与所述螺纹盲孔螺纹段和所述锥孔相匹配的刀具螺纹段和刀具锥段；
所述蜂窝芯超声切削刀柄按照以下位移分布曲线布置：所述法兰盘和所述一二级变幅杆定位锥面位于位移分布曲线的节点位置；所述超声切削刀具的切削刃处于位移分布曲线最大位移处；所述蜂窝芯超声切削刀柄的振动节点和位移分布曲线的设置，有效地减小了超声振动对于所述法兰盘、所述一二级变幅杆定位锥面的影响，最大限度的发挥所述蜂窝芯超声切削刀柄的切削效果，刀柄结构合理，布局紧凑。
所述超声切削刀具连接轴的外壁根据不同超声切削刀具的性能需求，可设计为圆锥形、圆柱形、圆锥圆柱复合形或指数、阶梯、悬链线、贝塞尔曲线等函数复合形成的外轮廓面。使用过程中，只需要更换所述二级变幅杆，即可实现不同超声切削系统的切换，降低了超声切削刀柄的制造和使用成本，提高了不同超声切削刀柄间的互换性。
所述超声电能传输机构包括套接在所述小轴段上的正极绝缘环，所述正极绝缘环的上端位于所述上端盖的下方，所述正极绝缘环的下端设有位于所述小轴段和所述中轴段之间的轴肩以及所述轴承内圈所构成的平面上的环形凸起，所述环形凸起将所述轴承内圈压在所述中轴段和所述大轴段之间的轴肩上，所述环形凸起上设有多个正极绝缘环冷却孔，所述小轴段上设有与所述正极绝缘环冷却孔连通的刀柄径向冷却孔，所述正极绝缘环上套接有正极导电环，所述正极导电环下端位于所述环形凸起上，所述正极绝缘环上设有正极绝缘环接线孔，所述小轴段上设有与所述正极绝缘环接线孔连通的刀柄接线孔，所述正极导电环上设有导线，所述导线的另一端依次穿过所述正极绝缘环接线孔和所述刀柄接线孔与所述换能器的正极连接，所述上端盖具有上端盖螺纹孔，所述上端盖螺纹孔内设有中空圆柱形负极连接件，所述中空圆柱形负极连接件的上端与固定端负极套筒的下端开口套接，所述固定端负极套筒的上端设有将所述固定端负极套筒压在所述中空圆柱形负极连接件的上端的固定端电极调整弹簧，所述固定端负极套筒的内底设有与其相匹配的固定端绝缘件，所述固定端绝缘件的下端内嵌有固定端正极，所述中空圆柱形负极连接件内套接有中空圆柱形电极绝缘限位件，所述 中空圆柱形电极绝缘限位件的内壁上部设有限位环形槽，所述中空圆柱形电极绝缘限位件内设有正极套筒，所述正极套筒的外壁设有与所述限位环形槽径向相匹配正极套筒法兰，所述正极套筒通过所述正极套筒法兰沿所述限位环形槽的轴向滑动，所述正极套筒内设有依次从所述正极套筒的下端开口和所述中空圆柱形电极绝缘限位件的下端伸出的正极碳刷，所述正极套筒内还设有将所述正极碳刷压在所述正极导电环上的正极电刷调整弹簧，所述正极套筒的下端与所述中空圆柱形电极绝缘限位件的下端内壁之间还设有将所述正极套筒的上端压在所述固定端正极上的正极调整弹簧；
所述上端盖与所述小轴段，所述上端盖与所述正极绝缘环的上端，所述下端盖与所述大轴段之间均具有间隙。
通过所述固定端电极调整弹簧、所述正极调整弹簧、所述正极电刷调整弹簧，所述固定端负极套筒和所述中空圆柱形负极连接件连接配合，实现超声电源正极和负极与超声切削刀柄可靠连接。
所述固定套与所述刀柄壳体之间采用所述轴承配合连接，所述刀柄壳体在机床主轴带动下，带动所述正极导电环旋转；所述上盖板、所述固定套、所述下盖板和所述超声电能传输机构(除所述正极绝缘环和所述正极导电环外)不旋转，所述正极碳刷在所述正极电刷调整弹簧的作用下，时刻保持接触，采用电刷滑环机构，一方面保证在旋转过程中，大功率超声电能可靠的传输给所述换能器，另一方面所述蜂窝芯超声切削刀柄的集成性更好，可以有效减小所述蜂窝芯超声切削刀柄尺寸和质量，避让开主轴端面空间，和尺寸干涉，方便自动换刀。正负极连接件在传输电能的同时也起到自适应接触状态和传递扭矩的作用，保证所述超声电能传输机构(除所述正极绝缘环和所述正极导电环外)不旋转。该超声电能传输机构的设计可以在快速更换的同时，无须对于拆卸电能传输机构，提高了自动化水平。
冷却气体通过所述刀柄中心冷却孔进入所述刀柄壳体内，所述内冷预紧螺栓内部可以通过冷却气体，更换二级变幅杆时，冷却气体进入所述阶梯孔，对所述一二级变幅杆连接螺纹孔和所述一二级变幅杆定位锥面起到清洁作用，提高锥面的配合精度，提高超声切削的能量的传递效率；所述一级变幅杆和所述二级变幅杆装配后，所述阶梯孔被封住，冷却空气从所述法兰冷却孔流出，流向所述超声切削刀具连接轴和所述超声切削刀具的连接处，将所述刀柄壳体中的所述换能器发热带走的同时，对所述超声切削刀具连接轴和所述超声切削刀具的连接处起到降温的作用；另一部分冷却空气通过所述刀柄径向冷却孔和所述正极绝缘环冷却孔，经由所述固定套和所述正极绝缘环之间的通路，流经所述轴承和所述正极电刷，在带走所述换能器热量的同时，从所述固定套冷却孔带走了因所述轴承旋转带来的发热，同时清洁了所述正极电刷与所述正极导电环间的接触区，降低了摩擦发热，提高了电能传输的稳定性。
所述大轴段内壁下端设有容纳所述法兰盘的环形沉台，所述蜂窝芯超声切削刀柄还包括 法兰端盖，所述法兰端盖通过法兰紧固螺栓将所述法兰盘压在所述环形沉台上，所述法兰冷却孔的轴线指向所述超声切削刀具连接轴和所述超声切削刀具的连接处。
超声切削系统与所述刀柄的连接面设置在所述法兰盘处；所述一级变幅杆整体在所述刀柄壳体内；所述二级变幅杆通过所述一级变幅杆与所述刀柄壳体连接，所述二级变幅杆整体在所述刀柄壳体外，这种刀柄壳体中只包含所述一级变幅杆的结构设计，有效地减小了所述蜂窝芯超声切削刀柄的外形尺寸和重量，解决了所述蜂窝芯超声切削刀柄在不同机床上的适用性。
所述二级变幅杆拆卸轴上设有扳手槽，所述超声切削刀具连接轴的外壁为圆锥形、圆柱形、圆锥圆柱复合形或指数、阶梯、悬链线、贝塞尔曲线等函数复合形成的外轮廓面。
所述一级变幅杆与所述二级变幅杆的直径比大于等于2，即所述一级变幅杆的直径与所述二级变幅杆前端的直径比大于等于2。
所述换能器和所述一级变幅杆的总长度(所述换能器后端到所述一级变幅杆前端)为四分之一波长的整数倍，所述二级变幅杆和所述超声切削刀具的总长度(所述二级变幅杆后端到所述超声切削刀具前端)为四分之一波长加上半波长的整数倍。
所述二级变幅杆连接螺纹轴与所述一二级变幅杆连接螺纹孔通过细牙螺纹连接，所述一二级变幅杆定位锥面为锥面角度大于0°小于90°的短锥面；所述螺纹盲孔螺纹段和所述刀具螺纹段通过细牙螺纹连接，所述锥孔为锥面角度大于0°小于90°的短锥面。
所述固定套冷却孔的轴线位于所述正极导电环的上方，所述正极绝缘环冷却孔的轴线位于所述正极导电环的下方。
所述刀柄标准接口通过刀柄拉钉与机床主轴连接，所述刀柄拉钉内设有与所述刀柄中心冷却孔连通的刀柄拉钉内冷孔，所述刀柄标准接口与所述刀柄拉钉螺纹连接。
所述中空圆柱形负极连接件的外壁设有与所述上端盖的上表面贴合的限位法兰；
所述中空圆柱形负极连接件的上端具有锥面，所述固定端负极套筒的下端开口具有开口环形槽，所述开口环形槽的槽底与所述中空圆柱形负极连接件的上端相匹配，所述开口环形槽的内壁与所述中空圆柱形负极连接件的外壁相匹配；
所述中空圆柱形电极绝缘限位件为分体结构，包括限位环和限位件主体，所述限位环的下表面与所述限位件主体的内壁上部构成所述限位环形槽；
所述正极套筒的上端呈锥台形。
负极电路回路部分：所述固定端电极调整弹簧上端与机床主轴端面(未给出)固定配合，并与超声电源负极相连接，下端与所述固定端负极套筒相连；所述固定端负极套筒为空心圆柱导电结构，下端与所述中空圆柱形负极连接件连接，所述中空圆柱形负极连接件与所述上盖板连接，使用过程中，所述固定端负极套筒在所述固定端电极调整弹簧的弹簧弹力作用下， 保证所述固定端负极套筒与所述中空圆柱形负极连接件可靠接触，所述开口环形槽的内壁与所述中空圆柱形负极连接件的外壁相匹配，之间的锥面接触实现了电极的自动调整定心功能，之间的圆柱面接触能够可靠克服在使用过程中因旋转产生的扭矩，保证了电能的安全可靠传输；工作过程中，超声电能负极流经所述固定端电极调整弹簧、所述固定端负极套筒、所述中空圆柱形负极连接件、所述上盖板、所述固定套、所述轴承、所述刀柄壳体、所述一级变幅杆导通，并通过所述一级变幅杆与所述环形陶瓷片组的负极导通，构成负极回路。
正极电路回路部分：所述固定端绝缘件整体为圆柱形导电结构，上端与所述固定端负极套筒的内底紧固连接配合，外壁与所述固定端负极套筒内壁紧固连接配合，另一侧端面为圆柱沉孔结构，内嵌所述固定端正极，所述固定端绝缘件起到了绝缘所述固定端负极套筒和所述固定端正极的作用；所述固定端正极的上侧与超声电源正极连接，下侧与所述正极套筒接触连接，进而通过正极电刷调整弹簧、正极电刷、正极导电环和导线与所述换能器的正极(即所述环形陶瓷片组的正极)导通。
所述正极套筒和所述中空圆柱形负极连接件之间设有所述中空圆柱形电极绝缘限位件，所述中空圆柱形电极绝缘限位件内的内壁下部与所述正极套筒外壁相配合，所述限位环形槽与所述正极套筒法兰径向相匹配，所述限位环形槽的轴向尺寸大于所述正极套筒法兰的厚度，使得所述正极套筒在径向方向上绝缘限位，轴向方向上有一定的伸缩调整量。
所述正极套筒的下端与所述中空圆柱形电极绝缘限位件的下端内壁之间还设有将所述正极套筒的上端压在所述固定端正极上的正极调整弹簧。
在所述正极调整弹簧弹力的作用下，所述正极套筒可沿轴向移动，以保证与所述固定端正极的可靠接触；所述蜂窝芯超声切削刀柄旋转过程中，所述正极电刷固定不动，所述正极导电环随所述蜂窝芯超声切削刀柄旋转，在所述正极电刷调整弹簧的作用下，所述正极电刷与所述正极导电环在旋转中时刻保持接触，实现电能的可靠传递。
所述蜂窝芯超声切削刀柄可作为独立部件，方便实现刀柄整体与机床主轴的连接与拆卸。
所述超声切削刀具包括刀具主体；
所述刀具主体的一端具有所述刀具锥段(以实现刀具与螺纹盲孔螺纹段同轴)，所述刀具锥段上设有与所述螺纹盲孔螺纹段相连的所述刀具螺纹段，所述刀具主体的另一端具有凹槽，所述凹槽包括锥形槽底、圆柱形孔和位于所述凹槽槽口的锥台形孔(以减小所述超声切削刀具外壁与蜂窝芯材料的摩擦)，所述锥形槽底和所述圆柱形孔之间设有圆弧过度段(以避免超声作用下的应力集中)，所述锥台形孔的小端与所述圆柱形孔连通；
所述锥台形孔和所述刀具主体远离所述刀具锥段一端的外壁构成喇叭形切削刃，所述刀具主体远离所述刀具锥段一端的外壁呈锥台形，所述刀具主体远离所述刀具锥段一端的外壁的小端位于所述圆柱形孔两端之间；
位于所述刀具锥段与所述锥形槽底之间的所述刀具主体外壁上设有扳手槽，靠近所述锥形槽底的所述圆柱形孔的一端设有至少一个从所述刀具主体外壁穿出的出屑口，所述圆柱形孔的靠近所述锥台形孔的孔段内壁设有至少一个从所述刀具主体外壁穿出的斜槽。
所述锥形槽底的槽口直径小于所述圆柱形孔的直径。
所述刀具螺纹段与所述螺纹盲孔螺纹段安装固定后，所述超声切削刀具与所述螺纹盲孔螺纹段同轴。所述螺纹盲孔螺纹段将轴向高频振动传递给所述超声切削刀具。
所述圆柱形孔的内壁设有向所述出屑口排屑的排屑槽，所述排屑槽与所述超声切削刀具的轴线平行或绕所述超声切削刀具的轴线由所述锥台形孔向所述出屑口螺旋上升。
根据实际应用中蜂窝芯材料的低、中、高三种不同硬度，所述排屑槽选择无槽结构、平直结构和螺旋结构。
所述刀具锥段到所述锥台形孔的大端之间的长度为声波在所述超声切削刀具材料传播波长的0.25～0.5倍，太短则不能满足超声振动要求，太长则不能保证所述超声切削刀具轴向刚度。
所述喇叭形切削刃的楔角为2～10°。
所述斜槽向所述刀具锥段方向倾斜，所述斜槽的个数为三个或三个以上，所述斜槽互相平行且沿所述超声切削刀具轴线等间距排列，所述斜槽之间的间距小于声波在所述超声切削刀具材料中传播的波长，所述斜槽的作用是将从所述螺纹盲孔螺纹段传递而来的纵振转变成扭振和纵振叠加的形式传递给喇叭形切削刃，有利于切削加工时材料的去除。
所述超声切削刀具的周向均布有两个或两个以上的所述出屑口，所述出屑口为长边平行于所述超声切削刀具轴线的矩形口或长轴平行或倾斜于所述超声切削刀具轴线的椭圆形口，也可以为便于切屑排出的其他的形状。
所述扳手槽为长方形扳手槽且其所在平面平行于所述超声切削刀具的轴线。
所述超声切削刀具的材料为高速钢或硬质合金，以传递高频轴向振动。
与现有技术相比，本发明提出了一种具有大振幅输出能力的，同时考虑不同振动系统间的互换性要求的蜂窝芯超声切削刀柄，解决了超声切削刀柄在通用机床上的适用性难题，提高了超声切削的自动化水平；
超声振动的引入减小了蜂窝芯切削加工的切削力，有效抑制了蜂窝芯孔格压溃变形损伤，保证加工质量和加工精度；
超声振动可有效减小超声切削刀具磨损，降低了加工成本；
超声振动具有良好的减摩作用，可以保证超声切削刀具加工完成在提升过程中心部切屑自动滑出超声切削刀具，不会堆积在凹槽内部，不需要停机清理切削，保证加工连续性，极大提高加工效率；同时，凹槽内未及时排出的蜂窝芯切屑在加工过程中还可通过排屑槽经出 屑口排出，进一步解决蜂窝芯切削加工排屑困难的问题。
基于上述理由本发明可在蜂窝芯材料超声切削加工等领域广泛推广。
附图说明
为了更清楚地说明本发明实施例或现有技术中的技术方案，下面将对实施例或现有技术描述中所需要使用的附图做以简单地介绍，显而易见地，下面描述中的附图是本发明的一些实施例，对于本领域普通技术人员来讲，在不付出创造性劳动性的前提下，还可以根据这些附图获得其他的附图。
图1是本发明的实施例1中蜂窝芯超声切削刀柄的剖视图以及与之对应的位移分布曲线示意图。
图2是本发明的实施例1中蜂窝芯超声切削刀柄(除二级变幅杆和超声切削刀具外)的剖视图。
图3是图2的A部放大示意图。
图4是本发明的实施例1中超声电能传输机构的剖视图。
图5是本发明的实施例1中装配有大圆片刀的二级变幅杆剖视图。
图6是本发明的实施例1中装配有直刃尖刀的二级变幅杆剖视图。
图7是本发明的实施例1中装配有小圆片刀的二级变幅杆剖视图。
图8是本发明的实施例2中装配有超声切削刀具的二级变幅杆剖视图。
图9是本发明的实施例2中超声切削刀具的结构示意图。
图10是本发明的实施例2中超声切削刀具的剖视图。
图11是本发明的实施例3中超声切削刀具的剖视图。
图12是本发明的实施例4中超声切削刀具的剖视图。
图13是普通切削刀具加工蜂窝芯后的圆弧特征。
图14是本发明的实施例2中超声切削刀具加工蜂窝芯后的圆弧特征。
具体实施方式
为使本发明实施例的目的、技术方案和优点更加清楚，下面将结合本发明实施例中的附图，对本发明实施例中的技术方案进行清楚、完整地描述，显然，所描述的实施例是本发明一部分实施例，而不是全部的实施例。基于本发明中的实施例，本领域普通技术人员在没有做出创造性劳动前提下所获得的所有其他实施例，都属于本发明保护的范围。
实施例1
如图1-图7所示，一种蜂窝芯超声切削刀柄，包括刀柄，回转机构，换能器、一级变幅杆、二级变幅杆、超声切削刀具1和超声电能传输机构；
所述刀柄包括位于上端的刀柄标准接口2和位于下端的刀柄壳体，所述刀柄壳体的外壁 呈阶梯轴状，包括依次连接的小轴段3、中轴段4和大轴段5，所述小轴段3与所述刀柄标准接口2连接；所述刀柄标准接口2上设有延伸至所述小轴段3内的刀柄中心冷却孔6；
所述回转机构包括位于所述小轴段3外侧的上端盖7，位于所述大轴段5外侧的下端盖8和位于所述上端盖7外沿和所述下端盖8外沿之间且通过轴承9与所述中轴段4外壁连接的固定套10，所述固定套10上设有固定套冷却孔11，所述固定套10内壁设有将所述轴承9外圈压在所述下端盖8上的固定套环形凸起12；
所述一级变幅杆呈圆柱状，其下端外壁具有向外延伸且与所述大轴段5内壁连接的法兰盘13，所述法兰盘13的上端和下端分别设有环形隔振槽14，两个所述环形隔振槽14与所述一级变幅杆同轴且交错设置，所述法兰盘13上均布有多个法兰冷却孔15，所述一级变幅杆的轴线位置设有贯通所述一级变幅杆的阶梯孔，所述阶梯孔包括依次连接的一级变幅杆中心冷却孔16、一级变幅杆锥孔17、一二级变幅杆连接螺纹孔18和一二级变幅杆定位锥面19；
所述换能器包括具有中空结构的内冷预紧螺栓20，后盖板21和环形陶瓷片组22，所述内冷预紧螺栓20与所述一级变幅杆中心冷却孔螺纹16连接，且通过所述后盖板21将所述环形陶瓷片组22压在所述一级变幅杆后端；
所述二级变幅杆包括依次连接的二级变幅杆连接螺纹轴23，二级变幅杆配合锥面轴24，二级变幅杆拆卸轴25和超声切削刀具连接轴26，所述二级变幅杆连接螺纹轴23与所述一二级变幅杆连接螺纹孔18螺纹连接，所述二级变幅杆配合锥面轴24的外壁与所述一二级变幅杆定位锥面19相匹配，所述超声切削刀具连接轴26的下端具有连接所述超声切削刀具1的螺纹盲孔，所述螺纹盲孔包括螺纹盲孔螺纹段27和位于所述螺纹盲孔开口的锥孔28，所述超声切削刀具1的连接部具有与所述螺纹盲孔螺纹段27和所述锥孔28相匹配的刀具螺纹段和刀具锥段；
所述超声电能传输机构包括套接在所述小轴段3上的正极绝缘环29，所述正极绝缘环29的上端位于所述上端盖7的下方，所述正极绝缘环29的下端设有位于所述小轴段3和所述中轴段4之间的轴肩以及所述轴承9内圈所构成的平面上的环形凸起30，所述环形凸起30将所述轴承9内圈压在所述中轴段4和所述大轴段5之间的轴肩上，所述环形凸起30上设有多个正极绝缘环冷却孔31，所述小轴段3上设有与所述正极绝缘环冷却孔31连通的刀柄径向冷却孔32，所述正极绝缘环29上套接有正极导电环33，所述正极导电环33下端位于所述环形凸起30上，所述正极绝缘环30上设有正极绝缘环接线孔34，所述小轴段3上设有与所述正极绝缘环接线孔34连通的刀柄接线孔35，所述正极导电环33上设有导线36，所述导线36的另一端依次穿过所述正极绝缘环接线孔34和所述刀柄接线孔35与所述换能器的正极连接，所述上端盖7具有上端盖螺纹孔，所述上端盖螺纹孔内设有中空圆柱形负极连接件37，所述中空圆柱形负极连接件37的上端与固定端负极套筒38的下端开口套接，所述固定端负 极套筒38的上端设有将所述固定端负极套筒38压在所述中空圆柱形负极连接件37的上端的固定端电极调整弹簧39，所述固定端负极套筒38的内底设有与其相匹配的固定端绝缘件40，所述固定端绝缘件40的下端内嵌有固定端正极41，所述中空圆柱形负极连接件37内套接有中空圆柱形电极绝缘限位件，所述中空圆柱形电极绝缘限位件的内壁上部设有限位环形槽42，所述中空圆柱形电极绝缘限位件内设有正极套筒43，所述正极套筒43的外壁设有与所述限位环形槽42径向相匹配正极套筒法兰44，所述正极套筒43通过所述正极套筒法兰44沿所述限位环形槽42的轴向滑动，所述正极套筒43内设有依次从所述正极套筒43的下端开口和所述中空圆柱形电极绝缘限位件的下端伸出的正极碳刷45，所述正极套筒43内还设有将所述正极碳刷45压在所述正极导电环33上的正极电刷调整弹簧46，所述正极套筒43的下端与所述中空圆柱形电极绝缘限位件的下端内壁之间还设有将所述正极套筒43的上端压在所述固定端正极41上的正极调整弹簧47；
所述上端盖7与所述小轴段3，所述上端盖7与所述正极绝缘环29的上端，所述下端盖8与所述大轴段5之间均具有间隙。
所述大轴段5内壁下端设有容纳所述法兰盘13的环形沉台，所述蜂窝芯超声切削刀柄还包括法兰端盖48，所述法兰端盖48通过法兰紧固螺栓将所述法兰盘13压在所述环形沉台上，所述法兰冷却孔15的轴线指向所述超声切削刀具连接轴和所述超声切削刀具的连接处。
所述固定套冷却孔11的轴线位于所述正极导电环33的上方，所述正极绝缘环冷却孔31的轴线位于所述正极导电环33的下方。
所述二级变幅杆拆卸轴25上设有扳手槽49，所述超声切削刀具连接轴26的外壁为圆锥形、圆柱形、圆锥圆柱复合形(如图7所示)或指数(如图6所示)、阶梯(如图5所示)、悬链线、贝塞尔曲线等函数复合形成的外轮廓面。
所示超声切削刀具1的刀刃为大圆片刀(如图5所示)、直刃尖刀(如图6所示)或小圆片刀(如图7所示)。
所述一级变幅杆与所述二级变幅杆的直径比大于等于2，即所述一级变幅杆的直径与所述二级变幅杆前端的直径比大于等于2。
所述换能器和所述一级变幅杆的总长度为四分之一波长的整数倍，所述二级变幅杆和所述超声切削刀具1的总长度为四分之一波长加上半波长的整数倍。
所述二级变幅杆连接螺纹轴23与所述一二级变幅杆连接螺纹孔18通过细牙螺纹连接，所述一二级变幅杆定位锥面19为锥面角度大于0°小于90°的短锥面；所述螺纹盲孔螺纹段27和所述刀具螺纹段通过细牙螺纹连接，所述锥孔28为锥面角度大于0°小于90°的短锥面。
所述刀柄标准接口2通过刀柄拉钉50与机床主轴连接，所述刀柄拉钉50内设有与所述 刀柄中心冷却孔6连通的刀柄拉钉内冷孔51，所述刀柄标准接口2与所述刀柄拉钉50螺纹连接。
所述中空圆柱形负极连接件的外壁设有与所述上端盖的上表面贴合的限位法兰；
所述中空圆柱形负极连接件37的上端具有锥面，所述固定端负极套筒38的下端开口具有开口环形槽，所述开口环形槽的槽底与所述中空圆柱形负极连接件37的上端相匹配，所述开口环形槽的内壁与所述中空圆柱形负极连接件37的外壁相匹配；
所述中空圆柱形电极绝缘限位件为分体结构，包括限位环52和限位件主体53，所述限位环52的下表面与所述限位件主体53的内壁上部构成所述限位环形槽42；
所述正极套筒43的上端呈锥台形。
所述下端盖8与所述大轴段5之间的间隙内设有密封圈54。
实施例2
如图8-图10所示，一种蜂窝芯超声切削刀柄，其与实施例1所述的一种蜂窝芯超声切削刀柄的区别特征在于，所述超声切削刀具1包括刀具主体；
所述刀具主体的一端具有刀具锥段55，所述刀具锥段55上设有与所述螺纹盲孔螺纹段相连的所述刀具螺纹段56，所述刀具主体的另一端具有凹槽，所述凹槽包括锥形槽底57、圆柱形孔58和位于所述凹槽槽口的锥台形孔59，所述锥形槽底57和所述圆柱形孔58之间设有圆弧过渡段60，所述锥台形孔59的小端与所述圆柱形孔58连通；
所述锥台形孔59和所述刀具主体远离所述刀具锥段一端的外壁65构成喇叭形切削刃，所述刀具主体远离所述刀具锥段一端的外壁65呈锥台形，所述刀具主体远离所述刀具锥段一端的外壁65的小端位于所述圆柱形孔两端之间；
位于所述刀具锥段55与所述锥形槽底57之间的所述刀具主体外壁上设有扳手槽61，靠近所述锥形槽底57的所述圆柱形孔58的一端设有至少一个从所述刀具主体外壁穿出的出屑口62，所述圆柱形孔58的靠近所述锥台形孔59的孔段内壁设有至少一个从所述刀具主体外壁穿出的斜槽63。
所述圆柱形孔58的内壁设有向所述出屑口62排屑的排屑槽64，所述排屑槽64绕所述超声切削刀具1的轴线由所述锥台形孔59向所述出屑口62螺旋上升。
所述刀具锥段55到所述锥台形孔59的大端之间的长度为声波在所述超声切削刀具1材料传播波长的0.25～0.5倍。
所述锥台形孔59构成的喇叭形切削刃的切削刃楔角为2～10°。
所述斜槽63向所述刀具锥段55方向倾斜，所述斜槽63的个数为三个，所述斜槽63互相平行且沿所述超声切削刀具1轴线等间距排列，所述斜槽63之间的间距小于声波在所述超声切削刀具1材料中传播的波长。
所述超声切削刀具1的周向均布有两个所述出屑口62，所述出屑口62为长边平行于所述超声切削刀具1轴线的矩形口。
所述扳手槽61为长方形扳手槽且其所在平面平行于所述超声切削刀具1的轴线。
所述超声切削刀具1的材料为高速钢或硬质合金。
所述刀具锥段55为锥面。
本实施例用于高密度蜂窝芯加工，所述排屑槽64的螺旋方向与所述超声切削刀具1回转方向相反。由于蜂窝芯硬度较高，加工变形较小，每一次切削后的切屑芯的排出方向与所述超声切削刀具1回转方向相反，沿所述排屑槽64上升，下一次切削产生的切屑芯将其顶至所述出屑口62处排出，如此往复，实现自动排屑。
实施例3
如图11所示，一种蜂窝芯超声切削刀柄，其与实施例2所述的一种蜂窝芯超声切削刀柄的区别特征为所述超声切削刀具1无排屑槽。
本实施例用于低密度蜂窝芯，由于中低密度蜂窝芯的加工变形较大，所述凹槽内壁与蜂窝芯切屑之间摩擦力较小，在超声振动作用及超声减磨作用下，当一次切削完成后切屑芯会从所述凹槽中脱离，从而实现自动排屑。
图13和图14分别为普通切削刀具和本发明中超声切削刀具1切削加工蜂窝芯后的圆弧特征，可以对比看出本发明对蜂窝芯圆弧特征加工质量的明显改善。
实施例4
如图12所示，一种蜂窝芯超声切削刀柄，其与实施例2所述的一种蜂窝芯超声切削刀柄的区别特征为所述排屑槽64与所述超声切削刀具1的轴线平行。
本实施例用于中密度蜂窝芯，所述排屑槽64与所述超声切削刀具1的轴线平行，加工过程中，所述排屑槽64内的切屑在旋转作用下会有小部分分离，并沿所述排屑槽64至所述出屑口62排出，而未被切碎的残余切屑由于其直径比凹槽的直径小，在超声振动及超声减磨作用下会从所述凹槽中脱离，从而实现自动排屑。
最后应说明的是：以上各实施例仅用以说明本发明的技术方案，而非对其限制；尽管参照前述各实施例对本发明进行了详细的说明，本领域的普通技术人员应当理解：其依然可以对前述各实施例所记载的技术方案进行修改，或者对其中部分或者全部技术特征进行等同替换；而这些修改或者替换，并不使相应技术方案的本质脱离本发明各实施例技术方案的范围。

Claims (9)

  1. 一种蜂窝芯超声切削刀柄，其特征在于，包括刀柄，回转机构，换能器、一级变幅杆、二级变幅杆、超声切削刀具和超声电能传输机构；
    所述刀柄包括位于上端的刀柄标准接口和位于下端的刀柄壳体，所述刀柄壳体的外壁呈阶梯轴状，包括依次连接的小轴段、中轴段和大轴段，所述小轴段与所述刀柄标准接口连接；所述刀柄标准接口上设有延伸至所述小轴段内的刀柄中心冷却孔；
    所述回转机构包括位于所述小轴段外侧的上端盖，位于所述大轴段外侧的下端盖和位于所述上端盖外沿和所述下端盖外沿之间且通过轴承与所述中轴段外壁连接的固定套，所述固定套上设有固定套冷却孔，所述固定套内壁设有将所述轴承外圈压在所述下端盖上的固定套环形凸起；
    所述一级变幅杆呈圆柱状，其下端外壁具有向外延伸且与所述大轴段内壁连接的法兰盘，所述法兰盘的上端和下端分别设有环形隔振槽，两个所述环形隔振槽与所述一级变幅杆同轴且交错设置，所述法兰盘上均布有多个法兰冷却孔，所述一级变幅杆的轴线位置设有贯通所述一级变幅杆的阶梯孔，所述阶梯孔包括依次连接的一级变幅杆中心冷却孔、一级变幅杆锥孔、一二级变幅杆连接螺纹孔和一二级变幅杆定位锥面；
    所述换能器包括具有中空结构的内冷预紧螺栓，后盖板和环形陶瓷片组，所述内冷预紧螺栓与所述一级变幅杆中心冷却孔螺纹连接，且通过所述后盖板将所述环形陶瓷片组压在所述一级变幅杆后端；
    所述二级变幅杆包括依次连接的二级变幅杆连接螺纹轴，二级变幅杆配合锥面轴，二级变幅杆拆卸轴和超声切削刀具连接轴，所述二级变幅杆连接螺纹轴与所述一二级变幅杆连接螺纹孔螺纹连接，所述二级变幅杆配合锥面轴的外壁与所述一二级变幅杆定位锥面相匹配，所述超声切削刀具连接轴的下端具有连接所述超声切削刀具的螺纹盲孔，所述螺纹盲孔包括螺纹盲孔螺纹段和位于所述螺纹盲孔开口的锥孔，所述超声切削刀具的连接部具有与所述螺纹盲孔螺纹段和所述锥孔相匹配的刀具螺纹段和刀具锥段；
    所述超声电能传输机构包括套接在所述小轴段上的正极绝缘环，所述正极绝缘环的上端位于所述上端盖的下方，所述正极绝缘环的下端设有位于所述小轴段和所述中轴段之间的轴肩以及所述轴承内圈所构成的平面上的环形凸起，所述环形凸起将所述轴承内圈压在所述中轴段和所述大轴段之间的轴肩上，所述环形凸起上设有多个正极绝缘环冷却孔，所述小轴段上设有与所述正极绝缘环冷却孔连通的刀柄径向冷却孔，所述正极绝缘环上套接有正极导电环，所述正极导电环下端位于所述环形凸起上，所述正极绝缘环上设有正极绝缘环接线孔，所述小轴段上设有与所述正极绝缘环接线孔连通的刀柄接线孔，所述正极导电环上设有导线， 所述导线的另一端依次穿过所述正极绝缘环接线孔和所述刀柄接线孔与所述换能器的正极连接，所述上端盖具有上端盖螺纹孔，所述上端盖螺纹孔内设有中空圆柱形负极连接件，所述中空圆柱形负极连接件的上端与固定端负极套筒的下端开口套接，所述固定端负极套筒的上端设有将所述固定端负极套筒压在所述中空圆柱形负极连接件的上端的固定端电极调整弹簧，所述固定端负极套筒的内底设有与其相匹配的固定端绝缘件，所述固定端绝缘件的下端内嵌有固定端正极，所述中空圆柱形负极连接件内套接有中空圆柱形电极绝缘限位件，所述中空圆柱形电极绝缘限位件的内壁上部设有限位环形槽，所述中空圆柱形电极绝缘限位件内设有正极套筒，所述正极套筒的外壁设有与所述限位环形槽径向相匹配正极套筒法兰，所述正极套筒通过所述正极套筒法兰沿所述限位环形槽的轴向滑动，所述正极套筒内设有依次从所述正极套筒的下端开口和所述中空圆柱形电极绝缘限位件的下端伸出的正极碳刷，所述正极套筒内还设有将所述正极碳刷压在所述正极导电环上的正极电刷调整弹簧，所述正极套筒的下端与所述中空圆柱形电极绝缘限位件的下端内壁之间还设有将所述正极套筒的上端压在所述固定端正极上的正极调整弹簧；所述上端盖与所述小轴段，所述上端盖与所述正极绝缘环的上端，所述下端盖与所述大轴段之间均具有间隙。
  2. 根据权利要求1所述的蜂窝芯超声切削刀柄，其特征在于：所述二级变幅杆拆卸轴上设有扳手槽，所述超声切削刀具连接轴的外壁为圆锥形、圆柱形、圆锥圆柱复合形或指数、阶梯、悬链线、贝塞尔曲线等函数复合形成的外轮廓面。
  3. 根据权利要求1所述的蜂窝芯超声切削刀柄，其特征在于：所述一级变幅杆与所述二级变幅杆的直径比大于等于2，即所述一级变幅杆的直径与所述二级变幅杆前端的直径比大于等于2；所述换能器和所述一级变幅杆的总长度为四分之一波长的整数倍，所述二级变幅杆和所述超声切削刀具的总长度为四分之一波长加上半波长的整数倍。
  4. 根据权利要求1所述的蜂窝芯超声切削刀柄，其特征在于：所述二级变幅杆连接螺纹轴与所述一二级变幅杆连接螺纹孔通过细牙螺纹连接，所述一二级变幅杆定位锥面为锥面角度大于0°小于90°的短锥面；所述螺纹盲孔螺纹段和所述刀具螺纹段通过细牙螺纹连接，所述锥孔为锥面角度大于0°小于90°的短锥面。
  5. 根据权利要求1所述的蜂窝芯超声切削刀柄，其特征在于：所述固定套冷却孔的轴线位于所述正极导电环的上方，所述正极绝缘环冷却孔的轴线位于所述正极导电环的下方；
    所述刀柄标准接口通过刀柄拉钉与机床主轴连接，所述刀柄拉钉内设有与所述刀柄中心冷却孔连通的刀柄拉钉内冷孔，所述刀柄标准接口与所述刀柄拉钉螺纹连接。
  6. 根据权利要求1所述的蜂窝芯超声切削刀柄，其特征在于：所述大轴段内壁下端设有容纳所述法兰盘的环形沉台，所述蜂窝芯超声切削刀柄还包括法兰端盖，所述法兰端盖通过法兰紧固螺栓将所述法兰盘压在所述环形沉台上，所述法兰冷却孔的轴线指向所述超声切削 刀具连接轴和所述超声切削刀具的连接处。
  7. 根据权利要求1所述的蜂窝芯超声切削刀柄，其特征在于：所述中空圆柱形负极连接件的外壁设有与所述上端盖的上表面贴合的限位法兰；
    所述中空圆柱形负极连接件的上端具有锥面，所述固定端负极套筒的下端开口具有开口环形槽，所述开口环形槽的槽底与所述中空圆柱形负极连接件的上端相匹配，所述开口环形槽的内壁与所述中空圆柱形负极连接件的外壁相匹配；
    所述中空圆柱形电极绝缘限位件为分体结构，包括限位环和限位件主体，所述限位环的下表面与所述限位件主体的内壁上部构成所述限位环形槽；所述正极套筒的上端呈锥台形。
  8. 根据权利要求1所述的蜂窝芯超声切削刀柄，其特征在于：所述超声切削刀具包括刀具主体；
    所述刀具主体的一端具有所述刀具锥段，所述刀具锥段上设有与所述螺纹盲孔螺纹段相连的所述刀具螺纹段，所述刀具主体的另一端具有凹槽，所述凹槽包括锥形槽底、圆柱形孔和位于所述凹槽槽口的锥台形孔，所述锥形槽底和所述圆柱形孔之间设有圆弧过度段，所述锥台形孔的小端与所述圆柱形孔连通；
    所述锥台形孔和所述刀具主体远离所述刀具锥段一端的外壁构成喇叭形切削刃，所述刀具主体远离所述刀具锥段一端的外壁呈锥台形，所述刀具主体远离所述刀具锥段一端的外壁的小端位于所述圆柱形孔两端之间；
    位于所述刀具锥段与所述锥形槽底之间的所述刀具主体外壁上设有扳手槽，靠近所述锥形槽底的所述圆柱形孔的一端设有至少一个从所述刀具主体外壁穿出的出屑口，所述圆柱形孔的靠近所述锥台形孔的孔段内壁设有至少一个从所述刀具主体外壁穿出的斜槽。
  9. 根据权利要求8所述的蜂窝芯超声切削刀柄，其特征在于：所述圆柱形孔的内壁设有向所述出屑口排屑的排屑槽，所述排屑槽与所述超声切削刀具的轴线平行或绕所述超声切削刀具的轴线由所述锥台形孔向所述出屑口螺旋上升；
    所述刀具锥段到所述锥台形孔的大端之间的长度为声波在所述超声切削刀具材料传播波长的0.25～0.5倍，所述喇叭形切削刃的楔角为2～10°；
    所述斜槽向所述刀具锥段方向倾斜，所述斜槽的个数为三个或三个以上，所述斜槽互相平行且沿所述超声切削刀具轴线等间距排列，所述斜槽之间的间距小于声波在所述超声切削刀具材料中传播的波长；
    所述超声切削刀具的周向均布有两个或两个以上的所述出屑口，所述出屑口为长边平行于所述超声切削刀具轴线的矩形口或长轴平行或倾斜于所述超声切削刀具轴线的椭圆形口；
    所述扳手槽为长方形扳手槽且其所在平面平行于所述超声切削刀具的轴线；
    所述超声切削刀具的材料为高速钢或硬质合金。
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