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

摘要：

在蜂窝复合材料超声辅助切割系统设计中，针对大变幅系数超声变幅杆的设计及其与加工工具配合的问题，基于“代替法”，结合有限元评估技术，建立了超声变幅杆和加工刀具的连接结构设计方法。首先，基于超声辅助加工原理，设计了具有大变幅能力的阶梯-悬链型复合变幅杆。然后，基于“代替法”，研究变幅杆长度减小对变幅杆声学性能的影响规律。进而，基于有限元仿真技术，研究装配后声学系统的声学性能。最后，采用设计的超声辅助切割系统对蜂窝材料进行切割加工实验研究，发现切割面无毛刺，加工过程无粉尘产生，从而验证了设计的超声辅助切割声学系统的有效性。

关键词: 超声辅助, 蜂窝材料, 变幅杆, 代替法