超声辅助磨削杯形砂轮变幅器设计与试验*

超声辅助磨削在硬脆材料的加工中应用广泛。为研制以杯形砂轮为加工工具的超声辅助磨削主轴附件式工具系统,建立了杯形砂轮变幅器的理论模型,推导了其频率方程,并通过Matlab开发了杯形砂轮变幅器设计软件。利用该软件结合有限元分析对杯形砂轮变幅器进行了设计。将研制的杯形砂轮变幅器与BT40刀柄一体化外套筒、导电滑环装配组成了杯形砂轮超声辅助磨削主轴附件式工具系统。对该超声振动系统进行了阻抗分析试验及超声谐振试验,结果表明,该超声振动系统阻抗性能较好,能够使杯形砂轮产生稳定的超声振动,验证了所提出的设计方法的正确性,为主轴附件式超声磨削装置的设计提供了理论参考。     

微细深孔超声轴向振动钻削装置的设计

随着科学技术的不断发展，对孔的加工技术在机械制造领域中获得越来越广泛的运用，但与此同时，对孔的加工精度和表面质量也提出了更高的要求，特别是在不锈钢、耐热钢、钛合金、高温合金等难加工材料上加工精密微细深孔。实践表明，若采用传统的方法加工，则存在一系列难以解决的困难，例如切削温度高、散热难、钻头易引偏、折断、入钻定心难、排屑不畅以及出口毛刺多。而旋转超声轴向振动钻削技术作为特种复合加工技术的—种，在精密微细深孔加工实践中已表现出普通钻削无法比拟的工艺效果。正是为了解决普通钻削微细深孔的种种困难，对精密微细深孔旋转超声轴向振动钻削技术进行了深入研究。     

超声辅助滚压系统的设计与研究*

鉴于风力发电机组主轴的复杂工作情况和疲劳断裂失效形式,提出一种基于表面强化技术的超声辅助滚压加工系统;首先基于运动合成原理,获得了滚轮接触线的运动轨迹特征,并应用ANSYS/LS-DYNA软件分析了加工过程的特点;之后,基于一维振动理论、等效波长理论与牛顿迭代理论,推导了并求解了复合变幅杆的频率方程,实现了该复合变幅杆的纵向振动。通过对该变幅杆进行有限元仿真分析与振动特性测试,结果表明二者相对设计频率的偏差仅在0.817％以内。最后,通过对40Cr主轴进行超声辅助滚压测试,结果获得了粗糙度Ra 0.085μm和表面硬度32.2HRC的加工表面,较普通滚压加工粗糙度降低了69.1％,显微硬度提高了60％。     

超声辅助滚压系统研究

鉴于风力发电机组主轴的复杂工作情况和疲劳断裂失效形式,提出一种基于表面强化技术的超声辅助滚压加工系统。首先基于运动合成原理,获得了滚轮接触线的运动轨迹特征,并应用ANSYS/LS-DYNA软件分析了加工过程的特点。之后,基于一维振动理论、等效波长理论与牛顿迭代理论,推导并求解了复合变幅杆的频率方程,实现了该复合变幅杆的纵向振动。通过对该变幅杆进行有限元仿真分析与振动特性测试,结果表明二者相对设计频率的偏差仅在0.817%以内。最后,通过对40Cr主轴进行超声辅助滚压测试,获得了粗糙度Ra 0.085μm和表面硬度32.2 HRC的加工表面,较普通滚压加工粗糙度降低了69.1%,显微硬度提高了60%。     

超声振动车削装置设计

在切削加工领域，提高加工精度方法很多，其中一个非常重要的研究方向在于努力减小切削过程中的切削力和切削热。超声振动切削技术在降低切削力和切削热方面有重要的作用，可以较好地解决难加工材料、难加工零件以及精密加工等方面的一些工艺问题。为了推广应用这项新技术，文章基于超声振动切削理论，设计了一套超声振动车削装置，为实现黑色金属薄壁零件的精密加工提供了新的途径。     

基于LabView的监测系统在微细电火花加工中的应用

电火花加工过程中，间隙内进行能量转换，间隙状态的优劣直接影响脉冲电能的转换效果，在微细电火花加工过程中这种影响更加明显。同时，这也是评判放电加工是否顺利进行的主要标准。在科研生产过程中，需要对放电状态，特别是微细电火花放电加工过程中的波形进行研究，因此，组建了一套用于采集放电波形、检测放电状态的放电监测系统。     

LIGA—EDM复合技术的研究

提出LIGA-EDM复合技术技术,即采用LIGA技术制备工具电极的微细电火花加工技术,通过同步辐射尝试光刻得到的胶结构厚度达2mm深宽比约为100,使用电铸技术得到厚度达1mm的铜工县电极,利用该电极进行微细电火花加工实验,在不锈钢上加工出异形小孔阵列．     

工程——工程学科研究进展

本年度进行的工程设计是为保证产品在加工、装配、试验过程中能满足设计要求而进行的辅助产品的设计。开展了微细深孔钻削装置设计、装配装置设计、真空系统改进设计及振动试验夹具设计等，这些辅助产品对保证产品质量，按时地完成生产任务起到了重要作用。     

微型轴承内滚道超声辅助超精研磨系统的设计研究*

为了提高5G基站中微型轴承的精度和使用寿命,基于微型轴承外套圈结构特征提出一种超声振动辅助研磨轴承外圈滚道的加工工艺。通过坐标变换及运动合成,获得了振动研磨轴承外圈滚道的工作面轨迹特点,阐明了振动高效研磨的本质特征;之后,分别采用等效电路法和有限分析法,建立了振动系统的等效电路图与频率方程,分析了该系统模型的固有模态与谐响应特性;最后,通过对自行研制的超声辅助研磨系统分别进行振动特性测试和加工效果测试。结果表明,加工系统振动频率相对设计频率的误差率为10‰,超声振幅为12.95μm,加工轴承滚道的粗糙度和轮廓度较传统研磨加工分别降低了27.17%和24.1%。     

超声辅助搅拌摩擦焊仿真分析及实验

为解决传统的搅拌摩擦焊工艺存在的轴向压力过大、搅拌头易磨损、焊接表面存在缺陷等问题,设计了一种集搅拌头与夹心式纵扭超声振动换能器为一体的超声辅助搅拌摩擦焊工具头。对超声辅助搅拌摩擦焊工具头进行了模态分析与谐响应分析,确保换能器结构满足要求。应用仿真软件对超声辅助搅拌摩擦焊进行了流体场、温度场和声场仿真分析,验证了在搅拌摩擦焊过程中加入纵扭超声振动能够增强材料的软化率,提高焊接材料的塑性流动。搭建实验平台,进行了6061铝合金的超声辅助搅拌摩擦焊焊接实验。结果表明,纵扭超声的引入能够提高焊接过程中材料流动性,减小搅拌头的前进阻力和轴向压力,改善焊接表面质量。在焊头转速900 r/min、焊接速度1.4 mm/s、轴向压力2.6 kN、超声功率100 W时,焊接效果最好,能较好地应在铝合金、镁合金等焊接熔点比较低的轻金属焊接之中。     

使用Inventor软件的超声变幅杆模态分析

使用Inventor软件建立超声变幅杆三维实体模型,并利用软件中集成的ANSYS有限元分析模块对其进行了模态分析,得到变幅杆各阶振型和纵向振动固有频率。分析结果表明,固有频率的模态分析值与实测值接近。Inventor软件将形状设计与力学分析集为一体,方便了变幅杆的设计。     

圆锥型复合变幅杆优化及动力学特性

针对应用传统解析法设计复合变幅杆过于繁琐的问题,提出采用简便、有效的微积法对圆锥复合变幅杆进行设计,之后通过Ansys软件对其结构进行有限元分析。此外,基于Ansys优化设计功能对变幅杆进行优化修整,对优化前后变幅杆进行阻抗分析和振动性能测试,测试结果表明优化后变幅杆振动效果更佳。最后,应用Ansys软件对变幅杆进行动力学特性分析,得到了不同直径、不同面积系数下变幅杆放大系数、最大应力值,并对仿真结果进行分析后得出了其动力学参数与大端直径及面积系数之间的关系。     

Study on a novel omnidirectional ultrasonic cavitation removal system for Microcystis aeruginosa

Microcystis aeruginosa, as a typical alga, produces microcystin with strong liver toxicity, seriously endangering the liver health of human and animals. Inhibiting the bloom of the Microcystis aeruginosa in lakes becomes a significant and meaningful work. Ultrasonic cavitation is currently considered to be the most environmentally friendly and effective method for the removal of Microcystis aeruginosa. However, the commercialized ultrasonic algae removal systems require multi-Langevin transducers to achieve omnidirectional ultrasonic irradiation due to the single irradiation direction of the Langevin transducer, resulting in the complex design and high energy consumption. To achieve a low-cost, simple structure, and high-efficiency algae removal system, a novel omnidirectional ultrasonic cavitation removal system for Microcystis aeruginosa is proposed. The proposed system is major composed of a novel omnidirectional ultrasonic transducer, which generates the omnidirectional ultrasonic irradiation by its shaking-head motion coupled by two orthogonal bending vibration modes. Modal simulation, sound field simulation, and cavitation bubble radius simulation are first carried out to optimize the geometric sizes of the proposed transducer and verify the correctness of the omnidirectional ultrasonic irradiation principle. Then the vibration characteristics of the transducer prototype are measured by vibration tests and impedance tests. Finally, the feasibility and effectiveness of the proposed omnidirectional ultrasonic removal system for Microcystis aeruginosa are evaluated through the algae removal experiments. The experimental results exhibit that the algal cells damaged by ultrasonic irradiation from the proposed system do not have the ability to self-repair. In addition, the algal removal rates reached 55.41% and 72.97% after 30 min of ultrasonic treatment when the corresponding ultrasonic densities are 0.014 W/mL and 0.021 W/mL, respectively. The proposed omnidirectional ultrasonic algae removal system significantly simplifies the configuration and reduces energy consumption, presenting the potential promise of algae removal and environmental protection.     

二维振动方向变换器的耦合振动及其等效电路

二维振动方向变换器集功率合成和二维超声输出的功能于一体,在功率超声技术中具有重要的应用价值。然而,对于二维振动方向变换器的设计分析只有一种较为复杂的波动方程法。为此,本文研究了二维振动方向变换器的另外一种简明的设计分析方法——等效电路法。通过引入二维机械耦合系数和纵向力转换系数,利用力电类比原理建立了二维振动方向变换器的同相及反相二维耦合振动的统一等效电路模型。利用本文提出的设计方法,计算了两种不同材料的二维振动方向变换器的谐振频率,与有限元计算结果及实验测试结果一致,为该类超声振动系统的工程应用提供了一种简洁直观的设计分析方法。      

Two-dimensional coupled vibration and equivalent circuit of longitudinal-longitudinal orthogonal composite vibration direction converter

With the advantages of transmitting energy from multiple directions to one direction and transforming vibration from one source to multiple directions, the two-dimensional vibra?tion direction converter has important applications in power ultrasonic technology. However, for the complexity of using the wave equation to design and analysis the two-dimensional vibration direction converter, a concise equivalent circuit for the converter is investigated. By introducing the two-dimensional mechanical coupling coefficient and the longitudinal force transform coef?ficient, and using the electromechanical analogy principle, the equivalent circuit and resonance frequency equation of the two-dimensional vibration direction converter vibrating in anti-phase and in-phase two-dimensional coupled vibration are deduced. The resonance frequencies of the vibration direction converters of two different materials are calculated by using the proposed frequency equation, which are in agreement with the results from the finite element method and the experimental test. It provides a concise method for the design and applications of such ultrasonic vibration system.     

机载光电稳瞄平台减振技术研究北大核心CSCD

机载光电稳瞄平台受飞机作战环境的干扰因素,会引起设备环架的振动,对光电平台载荷视轴的稳定性及跟踪精度影响很大,减振的主要任务是有效隔离环境振动。与传统橡胶减振器比较,文章提出了一种新型机载光电稳瞄平台的柔性减振设计。并通过ANSYS仿真软件对新的减振模型进行了模态仿真分析,通过振动试验对设计的性能进行了有效评估,测试结果与仿真评估误差为0.56%,说明该设计对机载光电稳瞄平台具有减振性。     

基于2-2型压电复合材料的新型宽频带径向振动超声换能器

本文提出了一种基于2-2型压电复合材料的新型宽频带径向振动超声换能器,它主要由内金属圆环和外压电陶瓷复合材料圆环组成.首先利用Newnham串并联理论和均匀场理论推导了2-2型压电复合材料的等效参数;其次利用解析法得到了金属圆环和径向极化压电复合陶瓷圆环径向振动的机电等效电路;最后得到了换能器的六端机电等效电路,从而得到了换能器的频率方程.接着分析了换能器共振频率和反共振频率以及有效机电耦合系数与几何尺寸、两相体积占比的关系,采用仿真软件对新型换能器的径向振动进行了数值模拟.结果表明,利用解析法得到的共振频率和反共振频率与数值模拟结果吻合较好.此外,对换能器在水下的辐射声场进行了仿真研究,结果表明新型复合材料径向换能器相比传统纯陶瓷径向换能器,发射电压响应幅值更大,工作带宽提高接近一倍,声匹配更佳.     

3D FEM analyses of the ultrasonic transducer for controlled nanowire rotary driving

Controlled rotary driving of single nano objects is an important technology in the assembling of nano structures, handling of biological samples, nano measurement, etc. However, there have been little analyses on the ultrasonic transducers for the nano rotary driving, which makes the transducer’s optimization impossible. In this work, vibration characteristics of the ultrasonic transducer for rotary driving of single nanowires, which has been proposed by the authors’ group, are analyzed by the 3D finite element method (FEM), and some useful guidelines for designing the transducer are achieved. It is found that the working point still exists when the commonly used metal materials in ultrasonic transducers are used as the vibration transmission strip, and when the vibration transmission strip’s size changes. It is also found that the direction of the elliptical motion of the micro manipulating probe’s tip may be reversed by changing the size of the vibration transmission strip properly. In addition, to ensure the performance consistency of the device, the micro manipulating probe’s length L_m or driving frequency should be designed to avoid the resonance of the micro manipulating probe.     

FREE VIBRATION ANALYSIS OF A SPINNING FLEXIBLE DISK-SPINDLE SYSTEM SUPPORTED BY BALL BEARING AND FLEXIBLE SHAFT USING THE FINITE ELEMENT METHOD AND SUBSTRUCTURE SYNTHESIS

Free vibration of a spinning flexible disk-spindle system supported by ball bearing and flexible shaft is analyzed by using Hamilton's principle, FEM and substructure synthesis. The spinning disk is described by using the Kirchhoff plate theory and von Karman non-linear strain. The rotating spindle and stationary shaft are modelled by Rayleigh beam and Euler beam respectively. Using Hamilton's principle and including the rigid body translation and tilting motion, partial differential equations of motion of the spinning flexible disk and spindle are derived consistently to satisfy the geometric compatibility in the internal boundary between substructures. FEM is used to discretize the derived governing equations, and substructure synthesis is introduced to assemble each component of the disk-spindle-bearing-shaft system. The developed method is applied to the spindle system of a computer hard disk drive with three disks, and modal testing is performed to verify the simulation results. The simulation result agrees very well with the experimental one. This research investigates critical design parameters in an HDD spindle system, i.e., the non-linearity of a spinning disk and the flexibility and boundary condition of a stationary shaft, to predict the free vibration characteristics accurately. The proposed method may be effectively applied to predict the vibration characteristics of a spinning flexible disk-spindle system supported by ball bearing and flexible shaft in the various forms of computer storage device, i.e., FDD, CD, HDD and DVD.