关键词: 超声辅助, 蜂窝材料, 变幅杆, 代替法

Abstract:

A substitution method under help of the finite element method was proposed to solve the problem of the coupled design of a composite horn and the cutting tool of an ultrasonic acoustic system for the noomex honeycomb material cutting process. First, a stepped-catenoidal composite horn with high displacement amplification factor was designed by using the theory of elastic wave propagation and finite element analysis technique. Then, the influences of the horn length on the vibration characteristics were studied based on substitution method using finite element method. The performance of the ultrasonic vibration system was studied by using finite element method. Finally, the ultrasonic acoustic system was fabricated and the ultrasonic assisted cutting experiments were performed, and the nomex honeycomb materials were cut effectively by using  the designed system. The machined surface shows high surface quality which is smooth without burrs. Thus, the effectiveness of the designed cutting tools was demonstrated.

Key words: ultrasonic, nomex, horn, substitution method