【作者】 赵明；

【导师】 李艺；

【作者基本信息】 苏州大学 ， 精密仪器及机械， 2012， 硕士

【摘要】 在调研中发现模具行业的厂家急需不依赖于加工者技术水平并且加工效率高的新型抛光设备，尤其在注塑模具中，模具内腔表面质量的抛光是模具加工中的瓶颈。超声抛光技术是一种有效的模具精加工技术，本课题致力于研究一种超声自动抛光方法用以解决上述问题。超声自动抛光是通过换能器将超声波发生器产生的超声振动传递到变幅杆，变幅杆再将振幅放大后传递给磨料悬浮液，悬浮液磨粒对工件表面撞击而达到抛光的目的。模具材料属于弹塑性材料，现在对于这类材料的超声抛光机理的研究极少，本课题对此做出了一些基础性研究。变幅杆是超声自动抛光设备中非常关键的一个部分，由于外界的影响和新设备需要更换不同的加工工具头，因此重点研究了激励频率变化对变幅杆的影响和工具头更换对变幅杆的影响程度。本文为超声自动抛光设备变幅杆的设计和优化提供了一整套完整的解决方案。本文总结了相关内容的研究和应用，并开展了如下研究工作：（1）设计了超声自动抛光系统的主要组成部分，分别对各部分的结构和功能进行了阐述，选用压电式换能器作为超声自动抛光系统的换能器。（2）建立了全新的适用于韧性材料的超声加工材料去除机理模型，并引用实验与理论预测值进行了分析比较，为进一步的研究打下基础。（3）研究了常用的四种单一型变幅杆，推导了三段式复合变幅杆的设计公式，并对各类变幅杆进行了动态分析，总结比较了不同变幅杆的放大系数和稳定性。（4）提出了一种频率可调的装配式复合变幅杆，对稳定性好的圆锥形变幅杆进行了放大系数的优化设计，提出了加有工具头后的变幅杆共振频率的优化设计方法，为适用于不同加工工况的变幅杆的优化设计提供了一种准确高效的解决方案，并研究了工具头磨损和工具头的更换对于变幅杆系统的影响。更多还原

【Abstract】 During the research, we find the mold manufacturers eagerly need a new kind ofpolishing equipment with high processing efficiency which is not depend on the worker’sskill. Especially about the injection mold, it is the bottleneck to improve the mold surfacequality of mold processing. Ultrasonic polishing technology is an effective mold finishingtechniques, and an ultrasonic automatic polishing method is developed to solve the aboveproblem.The principle of ultrasonic automatic polishing is that the ultrasonic generatorgenerates the ultrasonic vibration which is transmitted to the horn through the transducer,and then the horn drives the abrasives in abrasive suspension after the horn amplifies thevibration amplitude so that the abrasives hit surface of mold to decrease the roughness ofthe surface.Some basic work has been done in the polishing mechanism for elastic-plasticmaterial that mold steel belongs to, where little research has been done until today. Inaddition, ultrasonic horn is a very critical part in ultrasonic polishing. New equipmentdemand the horn that is not sensitive to the frequency fluctuations caused by externalchanges or replacement of the tool head linked to the horn, this article will also focus onthis area. A complete set of solutions of design and optimization of the ultrasonic automaticpolishing horn is provided.The relevant researches and applications are summarized and the following researchesare carried out.(1)The ultrasonic automatic polishing system’s main components are designed, thevarious parts of the structure and function are described, and the piezoelectric transducer isselected as the ultrasonic polishing system transducer.(2) A new ductile materials removal mechanism model in ultrasonic machining isestablished, the values of the reference experiment and those of theoretical predictionsmeet very well, which lay the foundation for further research. (3) Four kinds of single-type horn are studied, three sections composite horn designformulas are derived, the dynamic characteristics of various types of horn are analyzed,and the amplification factor and stability of different horns are studied.(4) A composite assembly horn adapted to the frequency adjustment is proposed isproposed, the amplification factor of the conical horn is optimized, the optimal designmethod to the resonance frequency horn is created, which provides an accurate andefficient design solution for horns used in different conditions and the effect of the wear ofthe tool linked to horn is studied, the impact of tool head wear and the replacement of thetool head for the horn system is analyzed.更多还原