INTRODUCTION FOR ADVANCED ULTRASONIC MILLING TECHNOLOGY
Ultrasonic high-frequency vibration milling technology is an advanced CNC turning machining technology that was born soon. A special cutting technology that uses ultrasonic waves to drive the tool to a high frequency of 20-40KHz and vibrates along the cutting direction at a high speed. Nowadays it is in the industrial production field. Has been favored by users at home and abroad.
* Major components of ultrasonic milling equipment
1.tool;
2.rotary bearings;
3.protect the shell;
4.conductive devices;
5.signal line;
6.ultrasonic vibration head;
7.chucks;
8.intelligent drive power;
9.fixed institutions;
10.other parts.
*Principle of ultrasonic milling technology
Ultrasonic high frequency vibration cutting is a kind of pulse cutting from the microscopic point of view. In macro view, it is a milling cutter loaded with ultrasonic high-frequency vibration mechanical energy. In a vibration cycle, the effective cutting time of the tool is very short, and the tool is completely separated from the workpiece and the chip in more than 80% of the time. The tool is in intermittent contact with the workpiece and the chip. This results in less friction on the tool, greatly reduced heat generation, and a significant reduction in cutting force. This avoids the “knife” phenomenon during normal cutting and does not generate built-up edge. .
With this kind of vibration milling, precision machining can be performed on an ordinary machine tool, and the tolerance of roundness, cylindricity, flatness, parallelism, straightness, etc., depends mainly on the accuracy of the spindle and the guide rail of the machine tool, and can achieve close to zero error. It is possible to use a vehicle to grind, drill to replace a hinge, and to mill to grind. Compared with high-speed hard cutting, high machine rigidity is not required and the metallographic structure of the workpiece surface is not damaged. In the finishing of curved contour parts, contour machining can be performed by means of CNC lathes, machining centers, etc., which can save the purchase cost of expensive CNC grinding machines.
*Ultrasonic technology milling device performance indicators
1. The cutting force is small, about 1/3-1/10 of the cutting force of ordinary tools. The
2. High processing accuracy depends mainly on the accuracy of the machine tool used, and the tolerance of the machined workpiece can be approached to the machine-related accuracy. The
3. The cutting temperature is low and the workpiece is kept at room temperature. The
4. No built-up edge, small workpiece deformation, no burrs. The
5. The cutting surface has a low roughness and can approach the theoretical roughness value up to Ra0.2. The
6. The “rigidity” of the machined part, ie, the increase in rigidity of the work piece compared to ordinary cutting.
7. The process is stable and can effectively eliminate chatter.
8. The cooling and lubrication of the cutting fluid increase. The
9. The tool life is several times to tens of times higher. The
10. The surface to be machined is in a state of compressive stress, and the fatigue strength, wear resistance, and corrosion resistance of the part are improved. The
11. The surface of the workpiece after cutting is quasi-inflection.
*Application
1. Forming and cutting: The use of forming cutting tools to process various types of contour surfaces and inner and outer spherical surfaces, excessive arcs, cones, etc.
2. Slender rods and thin-walled parts are machined.
3. Ultra-fine diameter parts turning. The
4. Ultra-precision machining.
Since ultrasonic high-frequency vibratory cutting technology has many advantages, it can be widely used in the machining of various difficult-to-machine materials such as aviation, aerospace, military, automotive, precision machinery manufacturing, high-precision mold production, and weapons manufacturing.
Difficult-to-cut material cutting: such as heat-resistant steel, titanium alloys, constant elastic alloys, high temperature alloys, stainless steel, chilled cast iron, engineering ceramics, composite materials, and granite.
Hardened steel parts and superhard parts can be processed with high precision and surface quality. Hard alloy tools can be used to easily process hardened steel parts with hardness above HRC60, such as high speed steel and bearing steel. PCD tooling carbide machining can greatly improve the tool's durability.
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