Supersonic processing technique (Ultrasonic Machining Technology)

The development that cutting efficiency raises the supersonic processing technique of 5 times -- Hermann Sauer and Deckel Maho company machine the breakthrough that go up in horniness brittleness material. The introduces stimulative treatment method change of new material is all Technical Division is undertaking new material try out studies, already entered practical change level. Industrial the high-powered data such as pottery and porcelain, optical glass, hard alloy has advantageous character. However, the accurate form cutting of these difficult cutting material, to making an extremely difficult question is for the technology. Because use the band of supersonic technology and advanced machine tool technology, her-mann Sauer company of Germany and Deckel Maho company offerred best settlement for this countermeasure. When material of the glass that uses difficult treatment, pottery and porcelain, hard alloy, the efficiency in treatment, finish machining is a problem. Because of these material mostly dispute conductor, not be report the object of processing technique. Same, technology of laser beam machining, because the foundation of treatment process is to use heat, consequently, cannot eliminate material to have fire damage and imperceptible chap, this also is a big question. Be in before in cutting method, want a course to work for long, ability reluctance satisfies treatment ask. Below this kind of circumstance, not only cutting tool wears away big, exterior quality is not good also. Be aimed at above problem, cadre is in Germany the Hermann Sauer company of mid Stipshausen developed brand-new supersonic processing technique, when processing hard brittleness data, cutting efficiency is 5 times of the method formerer. The foundation of the principle 　 new technology of method of new technology treatment is to be based on ultrasonic pilot to machine the supersonic treatment process of main shaft and union of newest treatment opportunity, be in former treatment process (boring, grinding, milling is machined) in sum high frequency and oscillatory campaign. The converter suppressing report of supersonic main shaft the electric and high frequency signal ultrasonic generator, according to suit to secure mechanical movement of frequency translate into at the resonance frequency 20kHz of various tool component (fore-and-aft and oscillatory) . This vibration sends amplifier from converter. This amplifier can get used to various need quantities, can control the amplitude of the journey. The clamp of conic form tool that passes patent is final transmit vibration to the tool entirely, namely diamond tool. When deepness is machined, produce every second to make an appointment with pulse 20000 times to move -- fore-and-aft motion is when outline is machined. Using supersonic when be being machined formerly, cutting process produces many heat in metal cutting as a result of attrition, imperceptible chap arises in the meeting on workpiece, from the consideration on quality, these workpiece still must undertake grinding is machined again, and the tool wears away very fast also. But, using supersonic when making concussion cutting machine, efficiency has 60 ％ about, 70 ％ are activationed. Consequently, circumgyrate tool motion does not have waste, its work with the eliminate at workpiece particle for the most part. Because hot impact is little, the osculatory time of the tool force of short, cutting is lesser, won't form chap and the attaint by the side of blade. Because use abrasive, improved exterior quality (highest Ra<0. 2 μ M) , can machine again elliptically, and, the bear of the tool and attrition also decrease. Still have an advantage, because of purify is tiny,cut bits and imperceptible fragment, can make clear lotion with water. After needing manson of special King Kong to provide supersonic component and tool clamp composition, the design of diamond tool is the key that decides supersonic treatment process is successful. Supersonic treatment, can assure cutting function on one hand, still can make the tool reachs long life on the other hand. Be opposite not only diamond abrasive, and to its combinative means raised special requirement. Prema DiaPDA665 of natural diamond abrasive is diamond is versed in bead is worn optimumly in providing. This kind grind bead tartly to be in get concussion bear from time to tome the good tiny character that break ring. Diamond tool has in machining a process from acute action. When Hermann Sauer company is making treatment of boring, grinding, milling use all sorts of tools, use wear bead to the diamond of 90 μ M from 6 μ M. To wear away the tool control is inside the smallest limit, this company is in special concatenate way was not developed below attaint tool circumstance, use at conveyer instrument vibration. This is called of glass and pottery and porcelain concatenate, install in solder of the drill rod below high vacuum; It is the technology that the fundamental material of bead of King Kong stone mill and tool combines, this kind of union is mechanical not only, also be chemical. Chemical union can prevent inchoate wear bead flake, have tall adhesion, and have in blade ministry utmost comes loose hot advantage. Have show the control system that teachs a function supersonic treatment asks to have from adaptive control function. For this, sauer company and Fagor company developed the numerical control device that supersonic treatment uses jointly. It is adaptive control character actually (ADR) and lung-power are controlled (ACC) , have 2 kinds to show the control method that teachs a function. Machine a requirement to suit, OK and individual use, OK also 2 are used at the same time. No matter be adaptive control and lung-power control, must suit at normally quantity of process management and the operational ton that process a process, control. Accordingly, it can in time spot outline error. Additional, of the tool wear away almost negligible also. Adaptive control, the tool becomes process pilot basis, this method can achieve optimum feed rate. ACC is received and run lung-power signal, for this, be in real time below treatment circumstance, can make process maximize. ACC is aimed at workpiece, use this method to basically be acquire best exterior quality. The union of ADR and ACC, to treatment exercise can provide best flexibility. When treatment, to gain the treatment speed of utmost, can use ADR, and when the exterior quality with best requirement, control system will be automatic switch is controlled to lung-power process (ACC) . This system, as the standard at present configuration deserves to install DMS 35 model with opportunity of DMS 50 supersonic treatment. The journey of opportunity of DMS 35 treatment is 240mm(Y axis) , 340mm(Z axis) with 350mm(X axis) ; And opportunity of DMS 50 treatment, the journey of X axis is 500mm. The power of electric machinery 1. 8 ／ 1. 100 ％ of ／ of 3kW(40 ％ ED Min) of ／ of 60 000r of option of Min(of ／ of 3000r of rotate speed of ED) , main shaft. Speed of the biggest feed can amount to 5000mm ／ Min. Because fixed frequency is 20kHz, can ensure frequency band is in 17. 5kHz arrives 21. Inside 5kHz limits. Finally, because supersonic treatment method has advantageous character, with machine methodological photograph formerly to compare, cutting quantity increases, feed function rises, productivity can add 4 times greatly most. Applied example is expanding for example, in respect of medical treatment technology (be like inside) of the examination that inspect looking glass, when must be made with optical glass, want to use this machine. Use the diamond reamer of opportunity of DMS 35 supersonic treatment, producible diameter 2mm, 202mm, the biggest length is the vitreous club of 160mm. When treatment, because material is phyletic different, can use treatment feed speed to be Min of ／ of 50mm of ～ of 25mm ／ Min, main shaft slewing speed is Min of ／ of 800 ～ 3000r. Use these to machine parameter, handling time is 1. 5min, 2min. Use machine a method formerly to need 2 times ～ the time of 3 times. The distinct advantage of this machine is to be able to use water to serve as refrigeration and clear lotion. When oil is being used previously, have the dangerous sex of fire, add the member that man-hour must configure surveillance. When opportunity of supersonic treatment of use DMS 35, can undertake alternate exercise a few months, realize successive and unmanned movement. Another example is with diamond reamer boring treatment makes semifinished product of diametical 12mm pottery and porcelain by zirconia. User requirement shortens substantially handling time. Machine a method before, blank with circumgyrate of 8000r ／ Min, min of ／ of feed speed 12mm. To achieve exterior quality RaO. The requirement of 4 μ M, undertake grinding even. When using supersonic treatment, main shaft rotate speed is 3000r ／ Min, feed rate can rise 4 times, it is 48mm ／ Min about, can achieve exterior quality requirement, do not need to undertake again grinding. Another example is to use supersonic treatment, the part that material of difficult to waiting by glass, pottery and porcelain, hard alloy treatment makes can undertake economy is machined. Jump over difficult treatment more forcedly, the effect is better. Eliminate pottery and porcelain, glass, hard alloy, all sorts of gem (corundum, agate, ruby) , enhance fiber the various data such as plastic, silicon, black lead can use method of this kind of supersonic treatment. CNC Milling