WO2021007924A1 - 一种用于超声加工的组合砂轮及其设计方法 - Google Patents

一种用于超声加工的组合砂轮及其设计方法 Download PDF

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Publication number
WO2021007924A1
WO2021007924A1 PCT/CN2019/103151 CN2019103151W WO2021007924A1 WO 2021007924 A1 WO2021007924 A1 WO 2021007924A1 CN 2019103151 W CN2019103151 W CN 2019103151W WO 2021007924 A1 WO2021007924 A1 WO 2021007924A1
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WIPO (PCT)
Prior art keywords
grinding ring
ring
hole
flange
outer grinding
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PCT/CN2019/103151
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English (en)
French (fr)
Inventor
康仁科
董志刚
王毅丹
朱祥龙
高尚
鲍岩
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大连理工大学
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Application filed by 大连理工大学 filed Critical 大连理工大学
Priority to US17/597,678 priority Critical patent/US20220324076A1/en
Publication of WO2021007924A1 publication Critical patent/WO2021007924A1/zh

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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B24—GRINDING; POLISHING
    • B24B—MACHINES, DEVICES, OR PROCESSES FOR GRINDING OR POLISHING; DRESSING OR CONDITIONING OF ABRADING SURFACES; FEEDING OF GRINDING, POLISHING, OR LAPPING AGENTS
    • B24B1/00—Processes of grinding or polishing; Use of auxiliary equipment in connection with such processes
    • B24B1/04—Processes of grinding or polishing; Use of auxiliary equipment in connection with such processes subjecting the grinding or polishing tools, the abrading or polishing medium or work to vibration, e.g. grinding with ultrasonic frequency
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B24—GRINDING; POLISHING
    • B24B—MACHINES, DEVICES, OR PROCESSES FOR GRINDING OR POLISHING; DRESSING OR CONDITIONING OF ABRADING SURFACES; FEEDING OF GRINDING, POLISHING, OR LAPPING AGENTS
    • B24B41/00—Component parts such as frames, beds, carriages, headstocks
    • B24B41/04—Headstocks; Working-spindles; Features relating thereto
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B24—GRINDING; POLISHING
    • B24D—TOOLS FOR GRINDING, BUFFING OR SHARPENING
    • B24D7/00—Bonded abrasive wheels, or wheels with inserted abrasive blocks, designed for acting otherwise than only by their periphery, e.g. by the front face; Bushings or mountings therefor
    • B24D7/10—Bonded abrasive wheels, or wheels with inserted abrasive blocks, designed for acting otherwise than only by their periphery, e.g. by the front face; Bushings or mountings therefor with cooling provisions
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B24—GRINDING; POLISHING
    • B24D—TOOLS FOR GRINDING, BUFFING OR SHARPENING
    • B24D7/00—Bonded abrasive wheels, or wheels with inserted abrasive blocks, designed for acting otherwise than only by their periphery, e.g. by the front face; Bushings or mountings therefor
    • B24D7/18—Wheels of special form

Definitions

  • the invention relates to the field of ultrasonic processing, in particular to a combined grinding wheel for ultrasonic processing and a design method thereof.
  • Ultrasonic assisted grinding technology is a new type of special processing technology that combines ultrasonic vibration with ordinary grinding wheel grinding. Research shows that ultrasonic-assisted grinding can change the material removal mechanism. During the machining process, it has the characteristics of low cutting force, low cutting heat, high tool durability, high machining efficiency, and good machining surface quality; in the complex shape of the cavity and surface As well as the processing field of hard and brittle materials such as thin walls, it has obvious processing advantages and is considered to be an effective way to process hard and brittle materials.
  • the grinding wheel is an important tool for ultrasonic-assisted grinding, and the ultrasonic grinding technology with a cup-shaped grinding wheel is the main method for processing hard and brittle materials.
  • the design of the existing ultrasonic cup-shaped grinding wheel does not fully consider and exert the ultrasonic effect, resulting in the unreasonable structural design of the grinding wheel, and it is difficult to meet the demand for high-quality and efficient processing of hard and brittle materials at the same time, mainly reflected in: 1) the existing ultrasonic cup
  • the grinding wheel has a single-layer cup-shaped structure. The effective grinding area of the grinding wheel is only within a small range of the outer annular surface of the grinding wheel.
  • the existing grinding wheel structure has a large enclosed space, which makes it difficult for cutting fluid to enter the grinding area inside the grinding wheel, resulting in low heat dissipation efficiency, which is not conducive to lowering the temperature of the grinding area; at the same time, the grinding debris during the grinding process is not easy to discharge, thus Affect processing quality and efficiency.
  • the purpose of the present invention is to provide a combined grinding wheel for ultrasonic processing and a design method thereof in the process of processing hard and brittle materials.
  • the combined grinding wheel of the present invention has two inner and outer vibrating units, and the accessory inner vibrating unit is connected with the connecting flange, which fully exerts the processing ability of ultrasonic auxiliary grinding and can improve the production efficiency; the inner vibrating unit has an active heat sink
  • connection flange is connected with the cone surface of the inner vibration unit, which reduces the loss of ultrasonic transmission between the interfaces, ensures the efficiency of ultrasonic transmission, and improves the positioning accuracy;
  • connection flange is connected to the cone of the inner vibration unit and has a certain degree Elasticity makes the axial height between the inner and outer vibrating units adjustable, which can meet a variety of working conditions.
  • the present invention adopts the following technical solutions:
  • a combined grinding wheel for ultrasonic processing including:
  • the outer grinding ring has a central cone hole and a plurality of outer grinding ring water holes located on the outer side of the central cone hole at the upper end, and the lower end has a water hole communicating with the central cone hole and the outer grinding ring and the lower end is open
  • the outer wall of the outer grinding ring corresponding to the outer grinding ring cavity has a plurality of outer grinding ring chute communicating with the outer grinding ring cavity, wherein the notch of the outer grinding ring chute is located Lower end surface of outer grinding ring;
  • the position of the water hole of the outer grinding ring coincides with the pitch diameter position when the outer layer is grinding the ring diameter.
  • the outer grinding ring has a pitch circle mode and a pitch diameter mode in the working frequency range, and the pitch diameter is uniformly distributed around the axis.
  • the water hole of the outer grinding ring can not only allow the grinding fluid to enter the inner vibration unit, but also reduce the energy loss caused by ineffective vibration and reduce the weight of the grinding ring.
  • the taper shank Connecting the taper shank, the lower end of which has a taper shank that extends from the central taper hole into the outer grinding ring cavity and is matched with the taper surface of the central taper hole.
  • the taper shank is located in the outer grinding ring cavity and is threaded to the outer wall of the taper section
  • conical or round nuts There are conical or round nuts, the upper end of the nut is in contact with the inner wall of the upper end of the outer grinding ring cavity;
  • the center of the outer grinding ring is a tapered hole, which is accurate and convenient for centering when it is matched with the tapered surface of the connecting tapered shank, which can make the outer grinding ring and the main shaft have better coaxiality; the tapered surface is connected more closely, and the transmission Ultrasonic vibration can reduce energy loss, thereby reducing heat generation and improving processing efficiency; and the conical surface connection has self-locking during ultrasonic vibration, making processing safer.
  • the connecting flange is located on the outside of the taper shank and fixed on the inner wall of the upper end of the outer grinding ring cavity, and has a central tapered through hole;
  • the inner vibrating unit has a conical surface matched with the conical surface of the central conical through hole and a central hole connected with the connecting cone shank by a screw, and the inner vibrating unit has a conical surface cooperating with the central conical through hole. Cone surface, realize the function of transmitting vibration and positioning;
  • the outer grinding ring chute is evenly distributed around the axis of the outer grinding ring, and the inclination angle of the outer grinding ring chute is 0° ⁇ 90°, the width is 1 ⁇ 10mm, and the groove depth is equal to The slot width ratio is 1-10.
  • the outer grinding ring chute can cause the longitudinal ultrasonic vibration transmitted by the horn to derive the ultrasonic amplitude along the tangential direction of the outer grinding ring, so that a single longitudinal ultrasonic vibration becomes a longitudinal torsion compound vibration, which makes the abrasive particle track more complicated and improves Processing quality, and the area of the oblique groove is larger than that of the straight groove, the heat dissipation effect is better, and it is more conducive to reducing the temperature of the grinding area.
  • the connecting taper shank is a stepped shaft composed of a coaxial cylindrical shank and a taper shank, and the cylindrical shank is located at the upper end of the taper shank and is used to connect with an ultrasonic tool holder;
  • the outer wall of the cylindrical shank is provided with a section of external thread connected with the relief nut;
  • the outer wall of the cone section of the cone shank located in the outer grinding ring cavity has a process groove
  • the upper part of the process groove is located in the central taper hole
  • the lower part of the process groove is located in the outer grinding ring cavity
  • the process groove functions as an undercut groove
  • the outer grinding ring is fastened on the cone surface with a nut, and the plane where the contact surface of the nut and the outer grinding ring is exactly passes through the process groove to isolate vibration and reduce The role of friction.
  • the connecting flange includes a flange end surface and an annular clamping portion located at the lower end of the flange end surface;
  • the flange end surface has a ring groove coaxial with the central tapered through hole, and the ring groove extends axially along the connecting flange to the annular clamping portion and divides the flange end surface into a method
  • the flange inner ring end face and the flange outer ring end face, the flange inner ring end face is lower than the flange outer ring end face, to ensure that the inner ring end face has enough movement space when the cone surface is deformed;
  • the annular clamping portion has a central tapered through hole extending to the end face of the inner ring of the flange, a plurality of straight grooves are evenly provided in the circumferential direction of the annular clamping portion, and the extending direction of the straight grooves and the connecting flange And the notches are located on the lower end surface of the annular clamping part;
  • the taper angle of the taper hole of the clamping portion is 45°-90°.
  • a plurality of process isolation grooves are uniformly provided on the end surface of the flange outer ring in the circumferential direction, and the process isolation grooves correspond to the pitch diameter positions of the outer layer grinding ring diameter mode;
  • the process isolation groove is fan-shaped, with a depth of 0.1 mm to 3 mm, and a central angle of 0° to 90°.
  • a rounded corner is provided between the end surface of the outer ring of the flange and the outer wall of the annular clamping portion, and the lower end of the rounded corner is lower than the bottom of the ring groove by more than 1 mm to ensure the transmission of ultrasonic energy.
  • the relief nut has a guide hole clearance fit with the cylindrical shank and an internal thread fit with the external thread.
  • the internal thread of the relief nut is matched with the external thread on the connecting taper shank, and the guide hole is in clearance fit with the cylindrical shank.
  • the inner vibrating unit is an active heat dissipation plate
  • the active heat dissipation plate includes a plate body, the plate body has the central hole and a plurality of active heat dissipation plate water holes located circumferentially outside the central hole;
  • the disk body outside the water hole of the active heat sink is provided with an annular protrusion coaxial with the disk body, and the outer wall of the annular protrusion constitutes a cone surface that matches the cone surface of the central cone through hole;
  • An active radiating plate undercut groove is arranged between the outer wall of the annular protrusion and the plate body.
  • the connecting flange deforms, the central conical through hole expands outward, and the active heat sink slides up along the central conical through hole.
  • the height adjustment of the active heat sink is realized; when the conical surface is in contact, the transmission efficiency of ultrasonic energy is high, and the problem of poor ultrasonic vibration of the active heat sink during threaded connection is solved.
  • the inner vibrating unit is an auxiliary inner grinding ring, the upper end of which has the central hole and a plurality of inner grinding ring water holes located on the circumferential outer side of the central hole, and the lower end has the central hole and the inner grinding ring.
  • the auxiliary inner grinding ring chip flutes are evenly distributed with the axis of the auxiliary inner grinding ring as the axis, which facilitates heat dissipation and chip removal; and as the shape of the chip flutes changes, the ultrasonic vibration mode of the inner grinding ring is assisted Will also change.
  • the lower outer wall of the auxiliary inner grinding ring is provided with an annular protrusion, the upper end surface of the annular protrusion and the lower end of the cylindrical cavity of the inner grinding ring cavity are located in the same plane, and the circumferential direction of the annular protrusion is provided Vertical groove communicating with the chip groove of the inner grinding ring;
  • a relief groove is provided between the upper outer wall of the auxiliary inner grinding ring and the upper end surface of the annular protrusion.
  • the active heat dissipation plate utilizes ultrasonic atomization to improve the heat dissipation capacity of the grinding wheel; the auxiliary inner grinding ring and the outer grinding ring form a double-layer grinding ring structure, and the height difference between the inner and outer grinding rings can be adjusted in one process Realize rough and fine machining and give full play to the grinding ability of ultrasonic assisted grinding.
  • the invention also discloses a method for designing a combined grinding wheel for ultrasonic machining as described above, which has the following steps:
  • the outer grinding ring selects the pitch mode, and when a smaller amplitude is required, the outer grinding ring selects the pitch diameter mode;
  • the determined working mode design the size of the outer grinding ring to achieve the required mode at the working frequency; determine the size of the inner vibration unit according to the size of the outer grinding ring so that it can be installed in the outer grinding ring In the ring cavity and there is a suitable axial adjustment;
  • the vibration unit has an appropriate axial adjustment amount
  • the connecting flange is designed according to the working mode of the outer grinding ring: the connecting flange can be divided into the pitch circle and the pitch diameter type, which are respectively suitable for the pitch circle mode and the pitch diameter mode of the outer grinding ring; the pitch circle connection method
  • the diameter of the inner ring of the flange is larger than the diameter of the outer grinding ring;
  • the end face of the pitch-diameter connecting flange has an isolation groove at the corresponding outer grinding ring diameter;
  • the connecting flange includes a flange end surface and an annular clamping part located at the lower end of the flange end surface;
  • the flange end surface has a ring groove coaxial with the central tapered through hole, and the ring groove extends axially along the connecting flange to the clamping portion and divides the flange end surface into flanges
  • the inner ring end face and the flange outer ring end face, the flange inner ring end face is lower than the flange outer ring end face, ensuring that the inner ring end face has enough movement space when the cone surface is deformed.
  • the annular clamping portion has a central tapered through hole extending to the end face of the inner ring of the flange, a plurality of straight grooves are evenly provided in the circumferential direction of the annular clamping portion, and the extending direction of the straight grooves and the connecting flange And the notches are located on the lower end surface of the annular clamping part;
  • the purpose of the annular groove and the straight groove is to weaken the rigidity of the annular clamping part and increase its deformability.
  • the taper angle of the taper hole of the clamping portion is 45°-90°.
  • the connecting flange includes a flange end surface and an annular clamping part located at the lower end of the flange end surface;
  • the flange end surface has a ring groove coaxial with the central tapered through hole, and the ring groove extends axially along the connecting flange to the clamping portion and divides the flange end surface into flanges
  • the inner ring end surface and the flange outer ring end surface, the flange inner ring end surface is lower than the flange outer ring end surface.
  • the annular clamping portion has a central tapered through hole extending to the end face of the inner ring of the flange, a plurality of straight grooves are evenly provided in the circumferential direction of the annular clamping portion, and the extending direction of the straight grooves and the connecting flange And the notches are located on the lower end surface of the annular clamping part;
  • the taper angle of the taper hole of the clamping portion is 45°-90°;
  • a plurality of process isolation grooves are uniformly provided on the end surface of the flange outer ring in the circumferential direction, and the process isolation grooves correspond to the pitch diameter positions of the outer grinding ring;
  • the process isolation groove is fan-shaped, with a depth of 0.1 mm to 3 mm, and a central angle of 0° to 90°.
  • the ultrasonic energy is input through the connecting cone shank, and part of it is transmitted to the outer grinding ring through the matching cone surface of the connecting cone shank and the outer grinding ring, and the amplitude is changed under the action of the outer grinding ring chute
  • the longitudinal ultrasonic vibration transmitted by the rod derives the ultrasonic amplitude along the tangential direction of the outer grinding ring, turning a single longitudinal ultrasonic vibration into a longitudinal torsional composite vibration; the other part of the ultrasonic energy passes through the connecting flange and vibrates with the inner layer through the connecting flange
  • the connection cone of the unit is transferred to the inner vibrating unit, so that the inner vibrating unit also generates ultrasonic vibration; the design method described fully considers the friction at the pitch circle, pitch diameter, and node.
  • the invention not only solves the problem of ultrasonic energy transmission of the combined grinding wheel, but also solves the problem of axial adjustment of the inner and outer layer vibration units.
  • the combined grinding wheel (with auxiliary inner grinding ring) for ultrasonic machining of the present invention can reduce the friction at the pitch circle and node, realize rough machining and finishing in one process, improve production efficiency, and change the inner and outer grinding ring
  • the grooved form can obtain different forms of ultrasonic vibration to meet different processing requirements and further improve the processing quality;
  • the combined grinding wheel (with active heat dissipation plate) for ultrasonic processing of the present invention conveniently realizes the compound vibration of the grinding wheel, and Use the characteristics of ultrasonic vibration for active cooling, enhance heat dissipation capacity, and improve grinding efficiency.
  • the present invention can be widely promoted in the field of ultrasonic processing.
  • Fig. 1 is a flow chart of the design method of the combined grinding wheel used for ultrasonic machining in embodiment 1 of the present invention.
  • Figure 2 is a modal analysis diagram of the outer grinding ring in Example 1 of the present invention (a. Pitch circle mode, b. Two pitch diameter mode).
  • Fig. 3 is a schematic diagram of the overall structure of the combined grinding wheel used for ultrasonic processing in Embodiment 1 of the present invention.
  • Fig. 4 is an exploded view of the combined grinding wheel used for ultrasonic machining in Embodiment 1 of the present invention.
  • Fig. 5 is a front view of the combined grinding wheel used for ultrasonic machining in Embodiment 1 of the present invention.
  • Fig. 6 is a sectional view taken along the line A-A in Fig. 5.
  • Figure 7 is an overall view of two forms of connecting flanges in Embodiment 1 of the present invention (a. Nodal circle connection flange; b. Two-nodal diameter connection flange).
  • Fig. 8 is a sectional view taken along the line B-B in Fig. 7.
  • Fig. 9 is a schematic diagram of the overall structure of the combined grinding wheel used for ultrasonic machining in Embodiment 2 of the present invention.
  • Figure 10 is an exploded view of the combined grinding wheel used for ultrasonic machining in Embodiment 2 of the present invention.
  • Fig. 11 is a front view of a combined grinding wheel used for ultrasonic processing in Embodiment 2 of the present invention.
  • Fig. 12 is a cross-sectional view taken along the line C-C in Fig. 11.
  • Fig. 13 is a front view of an active heat sink in Embodiment 2 of the present invention.
  • Fig. 14 is a cross-sectional view taken along the line D-D in Fig. 13.
  • a design method of a combined grinding wheel for ultrasonic processing has the following steps:
  • the size of the outer grinding ring 30 is designed on the basis of the combined grinding wheel modal to make it meet the modal requirements under working conditions.
  • the outer grinding ring 30 has a central taper hole at its upper end and a plurality of outer grinding ring water holes 33 located circumferentially outside the central taper hole 31, and its lower end has water passing through the central taper hole 31 and the outer grinding ring.
  • the outer grinding ring cavity 34 connected with the hole 33 and the lower end is open.
  • the outer wall of the outer grinding ring corresponding to the outer grinding ring cavity 34 has a plurality of outer grinding ring chutes 32 communicating with the outer grinding ring cavity 34, wherein , The notch of the outer grinding ring chute 32 is located on the lower end surface of the outer grinding ring 30;
  • the lower end of the connecting cone shank 20 has a central cone hole 31 extending into the outer grinding ring cavity 34 and is matched with the cone surface of the central cone hole 31
  • the taper shank of the taper shank is located in the outer wall of the outer grinding ring cavity 34 with a nut 40 threadedly connected with the upper end surface of the nut 40 and the inner wall of the upper end of the outer grinding ring cavity 34;
  • the type of connecting flange 50 is selected according to the working mode of the outer grinding ring 30.
  • the connecting flange 50 is located outside the tapered shank and fixed on the inner wall of the upper end of the outer grinding ring cavity 34, and has a central tapered through hole;
  • the inner vibrating unit is an auxiliary inner grinding ring 70.
  • the upper end of the auxiliary inner grinding ring 70 has a central hole and a plurality of inner peripherals located outside the central hole.
  • the lower end of the grinding ring water hole 72 has an inner grinding ring cavity 74 communicating with the central hole and the inner grinding ring water hole 72.
  • the upper outer wall 71 of the auxiliary inner grinding ring 70 and the central tapered through hole The lower end of the auxiliary inner grinding ring 70 has a plurality of inner grinding ring chip grooves 73, and the central hole is provided with a screw 90 connected to the lower end of the tapered shank.
  • the change of the solid force changes the height of the auxiliary inner grinding ring 70.
  • the designed combined grinding wheel for ultrasonic machining includes the retracted nut 10, the connecting taper shank 20, the outer grinding ring 30, the nut 40, the connecting flange 50, the flange fastening screw 60, and the auxiliary inner grinding ring 70 and a washer 80 and a screw 90 for fastening the auxiliary inner grinding ring.
  • the outer grinding ring 30 is matched with the connecting taper shank 20 through the central taper hole 31, and is locked with the nut 40; the connecting flange 50 is fixed on the inner wall of the upper end of the outer grinding ring cavity 34 by four screws 60, and the central hole of the connecting flange 50 is A central tapered through hole with a small taper, the upper outer wall 71 of the auxiliary inner grinding ring 70 is matched with the central tapered through hole through the tapered surface to transmit vibration and positioning; the auxiliary inner grinding ring 70 is fixed by a gasket 80 and a screw 90 are realized.
  • the screw 90 passes through the central hole of the washer 80 and the auxiliary inner grinding ring 70 and is fastened to the connecting taper shank 20.
  • the outer grinding ring chute 32 is equally spaced in the circumferential direction of the outer grinding ring 30, the inclination angle is 0° ⁇ 90°, the width is 1 ⁇ 10mm, and the ratio of groove depth to groove width is 1 ⁇ 10; the chute can change
  • the longitudinal ultrasonic vibration transmitted by the horn derives the ultrasonic amplitude along the tangential direction of the outer grinding ring, turning a single longitudinal ultrasonic vibration into a longitudinal torsion compound vibration, making the abrasive grain trajectory more complicated and improving the processing quality.
  • the area of the skew groove is larger than that of the straight groove, and the heat dissipation effect is better, which is more conducive to reducing the temperature of the grinding area.
  • At the lower end of the auxiliary inner grinding ring 70 equally spaced inner grinding ring chip grooves 73 are circumferentially opened to facilitate heat dissipation and chip removal.
  • the outer grinding ring 30 has four evenly distributed outer grinding ring water holes 33 whose positions coincide with the pitch diameter positions of the outer grinding ring 30 when the pitch diameter is two.
  • Figure 2 is the modal analysis diagram of the outer grinding ring.
  • the outer grinding ring has a pitch circle mode and a pitch diameter mode in the working frequency range. Take the two pitch diameter mode as an example, the two pitch diameters surround the axial direction Uniformly distributed.
  • the water hole 33 of the outer grinding ring can not only allow the grinding fluid to enter the auxiliary inner grinding ring 70, but also reduce the energy loss caused by ineffective vibration and reduce the weight of the grinding wheel.
  • the central taper hole 31 of the outer grinding ring 30 is accurately and conveniently centered when matched with the conical surface of the connecting taper shank, which can make the outer grinding ring 30 and the main shaft have better coaxiality; the conical surface is connected more closely, When ultrasonic vibration is transmitted, energy loss can be reduced, thereby reducing heat generation and improving processing efficiency; and the conical surface connection is self-locking during the ultrasonic vibration process, making the processing safer.
  • the connecting taper shank 20 is a stepped shaft composed of a coaxial cylindrical shank and a taper shank.
  • the cylindrical shank is used to connect with the spring chuck and can be quickly clamped to the ultrasonic tool shank; there is a section of external thread on the cylindrical shank to connect the retract nut 10.
  • the taper shank has a tapered thread, and the upper end of the taper thread has a process groove 22 with a width of 2mm and a depth of 1mm; the process groove 22 not only plays the role of an undercut groove, and when the outer grinding ring matches the connecting taper shank 20
  • the outer grinding ring 30 is fastened on the conical surface with the nut 40, and the plane where the contact surface of the nut 40 and the outer grinding ring 30 passes through the process groove 22, which has the effect of isolating vibration and reducing friction, as shown in the figure 6;
  • the threaded hole 21 is machined on the connecting taper shank 20 to connect with the screw 90 and fasten the auxiliary inner grinding ring 70.
  • the connecting flange 50 is available in different forms.
  • the mode of the outer grinding ring 30 at the working frequency is analyzed.
  • the mode is the pitch circle type
  • the pitch circle connection flange in Fig. 7 is used; when the mode is the two pitch diameter type, the figure is used 7.
  • the inner ring surface of the pitch circle connection flange is a tapered surface 51, that is, a central tapered through hole, with a cone angle of 45° to 90°.
  • the pitch-type connecting flange includes a flange end surface and an annular clamping portion located at the lower end of the flange end surface; the flange end surface has a ring groove 53 coaxial with the central tapered through hole, and the ring The groove 53 extends axially to the clamping portion along the pitch circle and divides the flange end surface into a flange inner ring end surface 54 and a flange outer ring end surface 55.
  • the flange inner ring end surface 54 is larger than the flange outer surface.
  • the ring end surface 55 is 0.2-0.5mm lower to ensure that the flange inner ring end surface 54 has enough movement space when the cone surface is deformed.
  • the annular clamping portion has a central tapered through hole extending to the inner ring end surface 54 of the flange.
  • the annular clamping portion is evenly provided with a plurality of straight grooves 52 in the circumferential direction.
  • the extending direction of the straight grooves 52 is the same as that of the
  • the axial direction of the pitch connecting flange is parallel and the notch is located on the lower end surface of the annular clamping part; the straight groove 52 and the ring groove 53 are used to weaken the rigidity of the pitch connecting flange and increase its deformation ability.
  • Two-pitch diameter connecting flanges have four more process isolation grooves 56 than pitch circle connecting flanges.
  • the four process isolation grooves 56 are evenly distributed around the axial direction, corresponding to the pitch diameter position of the outer grinding ring 30; process isolation grooves 56 is fan-shaped, with a depth of 0.1mm ⁇ 3mm and a central angle of 0° ⁇ 90°.
  • a rounded corner 57 is provided between the flange outer ring end surface 55 and the outer wall of the annular clamping portion, and the lower end of the rounded corner 57 is lower than the bottom of the ring groove 53 by more than 1 mm to ensure the transmission of ultrasonic energy.
  • the upper outer wall 71 of the auxiliary inner layer grinding ring 70 and the central tapered through-hole cone surface are matched with the layer grinding ring.
  • the auxiliary inner layer grinding ring 70 can be positioned; the gasket 80 is used.
  • the chip groove 73 facilitates heat dissipation and chip removal, and enriches the vibration shape of the auxiliary inner grinding ring 70.
  • the lower outer wall of the auxiliary inner grinding ring 70 is provided with an annular protrusion 75.
  • the upper end surface of the annular protrusion 75 and the lower end of the cylindrical cavity 77 of the inner grinding ring cavity 74 are located in the same plane.
  • 75 is provided with a vertical groove communicating with the inner grinding ring chip groove 73 in the circumferential direction;
  • a relief groove 76 is provided between the upper outer wall 71 of the auxiliary inner grinding ring 70 and the upper end surface of the annular protrusion 75.
  • Fig. 6 there is a section of guide hole 11 and a section of internal thread in the middle of the relief nut 10.
  • the internal thread of the relief nut 10 is matched with the external thread on the connecting taper shank 20, and the guide hole 11 is matched with the cylindrical shank of the connecting taper shank 20 with a small clearance.
  • a combined grinding wheel for ultrasonic processing is distinguished from the combined grinding wheel for ultrasonic processing in Example 1 in that the inner vibrating unit is an active heat sink 100, so
  • the active heat dissipation plate 100 includes a plate body 101, the upper end of the plate body 101 is provided with a cylindrical protrusion 102 and a plurality of active heat dissipation plate water holes 103 located outside the cylindrical protrusion 102 in the circumferential direction.
  • the lower end of the protrusion 102 has a groove for accommodating the head of the screw 90, and the upper end of the cylindrical protrusion 102 has the central hole passing through the bottom of the groove; the outer side of the active heat sink water hole 103
  • the disc body 101 is provided with an annular protrusion 104 coaxial with the disc body 101, and the outer wall of the annular protrusion 104 constitutes a conical surface that matches with the conical surface of the central conical through hole; the outer wall of the annular protrusion 104
  • An active heat dissipation plate undercut groove 105 is provided between the plate body 101 and the plate body 101.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Polishing Bodies And Polishing Tools (AREA)
  • Grinding And Polishing Of Tertiary Curved Surfaces And Surfaces With Complex Shapes (AREA)

Abstract

一种用于超声加工的组合砂轮及其设计方法，所述用于超声加工的组合砂轮包括：外层磨环（30），其上端具有中心锥孔（31）和多个位于中心锥孔（31）周向外侧的外层磨环通水孔（33）；连接锥柄（20），其下端具有由中心锥孔（31）伸入至外层磨环腔（34）且与中心锥孔（31）锥面配合的锥柄部；连接法兰（50），其位于锥柄部外侧且固定在外层磨环腔（34）上端内壁上，其具有中心锥形通孔；以及，内层振动单元（70/100），其具有与中心锥形通孔锥面配合的锥面和通过螺钉（90）与连接锥柄（20）连接的中心孔。通过组合砂轮内外振动单元的复合振动，提高砂轮的振动性能，实现材料的高效磨削加工。所述的设计方法由外层磨环（30）模态出发，依次确定各部分尺寸，最终得到组合砂轮，使砂轮的结构设计更合理。

Description

一种用于超声加工的组合砂轮及其设计方法 技术领域
本发明涉及一种涉及超声加工领域，具体地说是一种用于超声加工的组合砂轮及其设计方法。
背景技术
随着技术的进步，以陶瓷、碳化硅以及新型复合材料为代表的硬脆材料在航空、航天以及交通运输领域关键部件的制造中得到越来越广泛的应用。该类材料优良的化学及物理性能保证了其在恶劣工作环境下的使用性能，但是材料的硬脆特性则为加工带来了挑战。采用传统的磨削加工方法，磨削力大，材料容易出现表面裂纹，产生崩碎等加工缺陷，严重影响了加工质量；同时磨削区域温度高，刀具磨损严重，频繁更换刀具制约了加工效率的提高。因此，为了保证加工质量和效率，需要一种高质高效的加工方法来满足生产需求。
超声辅助磨削技术是将超声振动与普通砂轮磨削结合的一种新型特种加工技术。研究表明，超声辅助磨削可改变材料去除机理，在加工过程具有切削力小、切削热低、刀具耐用度高、加工效率高、加工表面质量好等特点；在形状复杂的型腔和型面以及薄壁等硬脆材料零件的加工领域，具有明显的加工优势，被认为是加工硬脆材料的有效途径。
砂轮是超声辅助磨削的重要工具，而采用杯形砂轮的超声磨削技术是硬脆材料加工的主要手段。但现有的超声杯形砂轮的设计没有充分考虑和发挥超声作用，导致砂轮的结构设计不合理，难以同时满足硬脆材料高质高效加工的需求，主要体现在：1)现有的超声杯形砂轮呈单层杯状结构，砂轮的有效磨削区域仅在砂轮的外圆环面的较小范围内，此时砂轮内部的大量区域不参与磨削，无法充分发挥杯形砂轮内部区域的磨削能力。2)超声磨削过程中，由于单一方向的超声纵向振动会影响材料加工质量。考虑到现有超声辅助磨削过程中使用的杯形砂轮结构简单，振动形式为单一的纵向振动形式，因此现有砂轮结构设计无法实现超声高质量加工的效果。3)砂轮在磨削过程中产生大量的热使磨削区域温度上升，影响加工质量和效率。现有砂轮的结构存在较大的封闭空间，使得切削液难以进入砂轮内部的磨削区域，导致散热效率较低，不利于降低磨削区域温度；同时磨削过程中的磨屑不易排出，从而影响加工质量和效率。
因此，为实现材料的高质高效加工，如何在充分考虑和利用超声加工特点的前提下，设计合理的砂轮结构，发挥砂轮内部区域超声作用对于材料的去除效果，在砂轮磨削过程中复合以多种超声振动形式，解决传统超声磨削砂轮的散热和排屑问题，是超声砂轮设计过程中需要解决的关键问题，也是对于超声砂轮的设计带来的挑战。
发明内容
本发明的目的在于在加工硬脆性材料的过程中，提供一种用于超声加工的组合砂轮及其设计方法。本发明的组合砂轮具有内外两层振动单元，采用附件化的内层振动单元与连接法兰连接，充分发挥了超声辅助磨削的加工能力，可以提高生产效率；内层振动单元有主动散热盘和辅助内层磨环两种类型，与外层磨环组合后可满足不同的加工需求；连接法兰形状及安装位置可根据外层磨环模态更换，以减少在节圆、节点处的摩擦；从而实现在砂轮外径上获得不同振幅和振动模态的超声振动，同时抑制砂轮连接等其他位置的超声振动。连接法兰内侧与内层振动单元锥面连接，减少了超声在界面间传递的损失，保证了超声传递的效率，同时提高了定位精度；连接法兰与内层振动单元锥面连接并有一定弹性，使内外层振动单元间轴向高度可调，能满足多种工况。
为解决上述技术问题，本发明采用如下技术方案：
一种用于超声加工的组合砂轮，包括：
外层磨环，其上端具有中心锥孔和多个位于中心锥孔周向外侧的外层磨环通水孔，其下端具有与中心锥孔和外层磨环通水孔连通且下端敞开的外层磨环腔，与外层磨环腔所对应的外层磨环外壁具有多个与外层磨环腔连通的外层磨环斜槽，其中，外层磨环斜槽的槽口位于外层磨环下端面；
所述外层磨环通水孔的位置与所述外层磨环节径时的节径位置重合。外层磨环在工作频率范围内有节圆式模态和节径式模态，节径环绕轴向均布。此时，外层磨环通水孔既能使磨削液进入内层振动单元，同时起到减少无效振动引起的能量损失以及磨环减重的作用。
连接锥柄，其下端具有由中心锥孔伸入至外层磨环腔且与中心锥孔锥面配合的锥柄部，所述锥柄部位于外层磨环腔内的锥段外壁螺纹连接有锥形或圆形螺母，所述螺母上端面与外层磨环腔上端内壁贴合；
外层磨环的中心为锥孔，在与连接锥柄的锥面配合时定心准确方便，能够 使外层磨环与主轴有较好的同轴度；锥面连接更为紧密，在传递超声振动时能减小能量的损失，从而减小热量的产生，提高加工的效率；并且锥面连接在超声振动过程中具有自锁性，加工更安全。
连接法兰，其位于锥柄部外侧且固定在外层磨环腔上端内壁上，其具有中心锥形通孔；
以及，内层振动单元，其具有与中心锥形通孔锥面配合的锥面和通过螺钉与连接锥柄连接的中心孔，所述内层振动单元具有与中心锥形通孔锥面配合的锥面，实现传递振动并且定位的功能；
所述外层磨环斜槽以所述外层磨环的轴线为轴均匀分布，且所述外层磨环斜槽的倾斜角度为0°～90°，宽度为1～10mm，槽深与槽宽比值为1～10。外层磨环斜槽能够使变幅杆传递的纵向超声振动衍生出沿外层磨环切向的超声振幅，使单一的纵向超声振动变为纵扭复合振动，使磨粒轨迹更复杂，提高加工质量，并且斜槽比直槽面积更大，散热效果更好，更有利于降低磨削区域的温度。
所述连接锥柄为由同轴的圆柱柄部和锥柄部构成的台阶轴，所述圆柱柄部位于所述锥柄部上端且用于与超声刀柄连接；
所述圆柱柄部外壁设有一段与退刀螺母连接的外螺纹；
所述锥柄部位于外层磨环腔内的锥段外壁具有工艺槽；
外层磨环与连接锥柄杆配合后，所述工艺槽上部位于中心锥孔内，所述工艺槽下部位于所述外层磨环腔内，所述工艺槽起到退刀槽的作用，并且当外层磨环与连接锥柄配合后，用螺母将外层磨环紧固在锥面上，螺母与外层磨环接触面所在平面恰好经过所述工艺槽，起到隔振和减少摩擦的作用。
所述连接法兰包括法兰端面和位于所述法兰端面下端的环形夹持部；
所述法兰端面具有与所述中心锥形通孔同轴的环槽，所述环槽沿所述连接法兰轴向延伸至所述环形夹持部且将所述法兰端面分隔成法兰内环端面和法兰外环端面，法兰内环端面比法兰外环端面低，保证锥面变形时内环端面有足够的运动空间；
所述环形夹持部具有延伸至法兰内环端面的中心锥形通孔，所述环形夹持部周向均匀设置有多个直槽，所述直槽的延伸方向与所述连接法兰的轴向平行且槽口位于所述环形夹持部的下端面；
所述夹持部锥孔的锥角为45°～90°。
当外层磨环在工作频率下的模态为节圆式时，采用上述连接法兰结构；当模态为节径式时，采用以下连接法兰结构：
所述法兰外环端面周向均匀设置有多个工艺隔离槽，且工艺隔离槽与所述外层磨环节径模态的节径位置对应；
所述工艺隔离槽呈扇形，深度为0.1mm～3mm，圆心角为0°～90°。
所述法兰外环端面与所述环形夹持部外壁之间设有圆角，所述圆角下端比所述环槽槽底低1mm以上，保证超声能量的传递。
所述退刀螺母具有与所述圆柱柄部间隙配合的导向孔和与所述外螺纹配合的内螺纹。安装时退刀螺母的内螺纹与连接锥柄上的外螺纹配合，导向孔与圆柱柄部间隙配合。退刀时旋转退刀螺母，即可将因锥面配合自锁的外层磨环顶开，方便磨环更换。
所述内层振动单元为主动散热盘，所述主动散热盘包括盘体，所述盘体具有所述中心孔和多个位于所述中心孔周向外侧的主动散热盘通水孔；所述主动散热盘通水孔外侧的所述盘体上设有与所述盘体同轴的环形凸起，所述环形凸起的外壁构成与中心锥形通孔锥面配合的锥面；所述环形凸起的外壁与所述盘体之间设有主动散热盘退刀槽。随着螺钉紧固力的增加，所述环形凸起的外壁对连接法兰的压力增加，连接法兰变形，中心锥形通孔向外扩张，主动散热盘沿中心锥形通孔上滑，实现主动散热盘的高度调节；锥面接触时，超声能量的传递效率高，解决了螺纹连接时主动散热盘超声振动不良的问题。
所述内层振动单元为辅助内层磨环，其上端具有所述中心孔和多个位于所述中心孔周向外侧的内层磨环通水孔，其下端具有与所述中心孔和内层磨环通水孔连通的内层磨环腔，所述辅助内层磨环上侧外壁构成与中心锥形通孔锥面配合的锥面，所述辅助内层磨环下端面具有多个内层磨环排屑槽；
所述辅助内层磨环排屑槽以所述辅助内层磨环的轴线为轴均匀分布，方便散热与排屑；并且随着排屑槽形状的改变，辅助内层磨环的超声振动形式也会改变。
所述辅助内层磨环下侧外壁设有环形凸起，所述环形凸起的上端面与所述内层磨环腔的圆柱形腔下端位于同一平面内，所述环形凸起的周向设有与内层磨环排屑槽连通的竖直槽；
所述辅助内层磨环上侧外壁与所述环形凸起上端面之间设有退刀槽。
随着螺钉紧固力的增加，辅助内层磨环上侧外壁对连接法兰的压力增加， 连接法兰变形，中心锥形通孔向外扩张，辅助内层磨环沿中心锥形通孔上滑，实现辅助内层磨环的高度调节；锥面接触时，超声能量的传递效率高，解决了螺纹连接时辅助内层磨环超声振动不良的问题。
所述主动散热盘利用超声雾化作用，可提高砂轮的散热能力；辅助内层磨环与外层磨环组成双层磨环结构，通过调节内外磨环端面的高度差，可在一道工序中实现粗精加工，充分发挥超声辅助磨削的磨削能力。
本发明还公开了一种如上述所述的用于超声加工的组合砂轮的设计方法，具有如下步骤：
由加工要求，确定组合砂轮的振动模态，当需要较大振幅时，外层磨环选择节圆模态，当需要较小的振幅时外层磨环选择节径模态；
根据已确定的工作模态，设计外层磨环尺寸，使其在工作频率下实现所需模态；根据外层磨环的尺寸确定内层振动单元的尺寸，使其能够装入外层磨环腔内且有合适的轴向调整量；
根据内层振动单元和外层磨环的尺寸确定连接锥柄的尺寸，保证内层振动单元和外层磨环连接后外层磨环与锥柄接触处是超声波长的节点位置，且内层振动单元有合适的轴向调整量；
确定外层磨环通水孔位置：外层磨环通水孔位置与外层磨环节径模态时的节径位置重合；
根据外层磨环工作模态设计连接法兰：连接法兰可分为节圆式与节径式，分别适用于外层磨环的节圆模态和节径模态；节圆式连接法兰内环直径大于外层磨环节圆直径；节径式连接法兰的端面在对应外层磨环节径处开隔离槽；
将设计完成的各零部件装配，即得到用于超声加工的组合砂轮。
若选择外层磨环工作模态为节圆模态时，所述连接法兰包括法兰端面和位于所述法兰端面下端的环形夹持部；
所述法兰端面具有与所述中心锥形通孔同轴的环槽，所述环槽沿所述连接法兰轴向延伸至所述夹持部且将所述法兰端面分隔成法兰内环端面和法兰外环端面，法兰内环端面比法兰外环端面低，保证锥面变形时内环端面有足够的运动空间。
所述环形夹持部具有延伸至法兰内环端面的中心锥形通孔，所述环形夹持部周向均匀设置有多个直槽，所述直槽的延伸方向与所述连接法兰的轴向平行且槽口位于所述环形夹持部的下端面；
所述环槽和所述直槽的设置目的为减弱环形夹持部刚度，增加其变形能力。
所述夹持部锥孔的锥角为45°～90°。
若选择外层磨环工作模态为节径模态时，所述连接法兰包括法兰端面和位于所述法兰端面下端的环形夹持部；
所述法兰端面具有与所述中心锥形通孔同轴的环槽，所述环槽沿所述连接法兰轴向延伸至所述夹持部且将所述法兰端面分隔成法兰内环端面和法兰外环端面，法兰内环端面比法兰外环端面低。
所述环形夹持部具有延伸至法兰内环端面的中心锥形通孔，所述环形夹持部周向均匀设置有多个直槽，所述直槽的延伸方向与所述连接法兰的轴向平行且槽口位于所述环形夹持部的下端面；
所述夹持部锥孔的锥角为45°～90°；
所述法兰外环端面周向均匀设置有多个工艺隔离槽，且工艺隔离槽与所述外层磨环的节径位置对应；
所述工艺隔离槽呈扇形，深度为0.1mm～3mm，圆心角为0°～90°。
所述的组合砂轮在工作时超声能量经连接锥柄输入，一部分通过连接锥柄与外层磨环的配合锥面传递给外层磨环，并在外层磨环斜槽的作用下使变幅杆传递的纵向超声振动衍生出沿外层磨环切向的超声振幅，使单一的纵向超声振动变为纵扭复合振动；另一部分超声能量则通过连接法兰，经由连接法兰与内层振动单元的连接锥面传递给内层振动单元，使内层振动单元也产生超声振动；所述的设计方法充分考虑了节圆、节径、节点处的摩擦。
本发明既解决了组合砂轮的超声能量传递为题，又解决了内外层振动单元的轴向调整问题。
本发明的用于超声加工的组合砂轮(具有辅助内层磨环)可减少节圆、节点处的摩擦，实现在一道工序中进行粗加工与精加工，提高生产效率，改变内外层磨环的开槽形式，可以得到不同形式的超声振动，以满足不同的加工要求，进一步提高加工质量；本发明的用于超声加工的组合砂轮(具有主动散热盘)便捷的实现了砂轮的复合振动，并且利用超声振动的特性进行主动冷却，增强散热能力，提高磨削效率。
基于上述理由本发明可在超声加工等领域广泛推广。
附图说明
为了更清楚地说明本发明实施例或现有技术中的技术方案，下面将对实施 例或现有技术描述中所需要使用的附图做以简单地介绍，显而易见地，下面描述中的附图是本发明的一些实施例，对于本领域普通技术人员来讲，在不付出创造性劳动性的前提下，还可以根据这些附图获得其他的附图。
图1是本发明的实施例1中用于超声加工的组合砂轮的设计方法流程图。
图2是本发明的实施例1中外层磨环的模态分析图(a.节圆模态，b.二节径模态)。
图3是本发明的实施例1中用于超声加工的组合砂轮的整体结构示意图。
图4是本发明的实施例1中用于超声加工的组合砂轮的***图。
图5是本发明的实施例1中用于超声加工的组合砂轮的主视图。
图6是图5中A-A向的剖视图。
图7是本发明的实施例1中连接法兰的两种形式的整体图(a.节圆式连接法兰；b.二节径式连接法兰)。
图8是图7中B-B向的剖视图。
图9是本发明的实施例2中用于超声加工的组合砂轮的整体结构示意图。
图10是本发明的实施例2中用于超声加工的组合砂轮的***图。
图11是本发明的实施例2中用于超声加工的组合砂轮的主视图。
图12是图11中C-C向的剖视图。
图13是本发明的实施例2中主动散热盘的主视图。
图14是图13中D-D向的剖视图。
具体实施方式
为使本发明实施例的目的、技术方案和优点更加清楚，下面将结合本发明实施例中的附图，对本发明实施例中的技术方案进行清楚、完整地描述，显然，所描述的实施例是本发明一部分实施例，而不是全部的实施例。基于本发明中的实施例，本领域普通技术人员在没有做出创造性劳动前提下所获得的所有其他实施例，都属于本发明保护的范围。
实施例1
如图1所示，一种用于超声加工的组合砂轮的设计方法，具有如下步骤：
首先判断工况，根据加工要求确定所需设计的组合砂轮模态，当需要较大振幅时选择节圆模态，当需要较小的振幅时选择节径模态，以二节径模态为例；以组合砂轮模态为依据设计外层磨环30的尺寸，使其在工作状态下满足模态要 求。所述外层磨环30，其上端具有中心锥孔和多个位于中心锥孔31周向外侧的外层磨环通水孔33，其下端具有与中心锥孔31和外层磨环通水孔33连通且下端敞开的外层磨环腔34，与外层磨环腔34所对应的外层磨环外壁具有多个与外层磨环腔34连通的外层磨环斜槽32，其中，外层磨环斜槽32的槽口位于外层磨环30下端面；
确定外层磨环通水孔33位置：外层磨环通水孔33位置与外层磨环二节径模态时的节径位置重合；
确定连接锥柄20与所述外层磨环30的连接关系，所述连接锥柄20，其下端具有由中心锥孔31伸入至外层磨环腔34且与中心锥孔31锥面配合的锥柄部，所述锥柄部位于外层磨环腔34内的锥段外壁螺纹连接有螺母40，所述螺母40上端面与外层磨环腔34上端内壁贴合；
根据外层磨环30工作模态选择连接法兰50类型，连接法兰50，其位于锥柄部外侧且固定在外层磨环腔34上端内壁上，其具有中心锥形通孔；
安装内层振动单元，本实施例中，所述内层振动单元为辅助内层磨环70，所述辅助内层磨环70，其上端具有中心孔和多个位于中心孔周向外侧的内层磨环通水孔72，其下端具有与中心孔和内层磨环通水孔72连通的内层磨环腔74，所述辅助内层磨环70上侧外壁71与中心锥形通孔锥面配合，所述辅助内层磨环70下端面具有多个内层磨环排屑槽73，所述中心孔上设有与所述锥柄部下端连接的螺钉90，随着螺钉90紧固力的变化，辅助内层磨环70的高度发生变化。
所设计的用于超声加工的组合砂轮，该结构包括退刀螺母10、连接锥柄20、外层磨环30、螺母40、连接法兰50、法兰紧固螺钉60、辅助内层磨环70以及用于紧固辅助内层磨环的垫片80和螺钉90。外层磨环30通过中心锥孔31与连接锥柄20配合，并用螺母40锁紧；连接法兰50通过四个螺钉60固定在外层磨环腔34上端内壁上，连接法兰50中心孔是一个锥度较小的中心锥形通孔，辅助内层磨环70的上侧外壁71通过锥面与中心锥形通孔配合，传递振动并且定位；辅助内层磨环70的固定则通过垫片80与螺钉90实现，螺钉90穿过垫片80和辅助内层磨环70的中心孔，紧固到连接锥柄20上。
在外层磨环30周向开有等间隔的外层磨环斜槽32，倾斜角度为0°～90°，宽度为1～10mm，槽深与槽宽的比值为1～10；斜槽能够使变幅杆传递的纵向超声振动衍生出沿外层磨环切向的超声振幅，使单一的纵向超声振动变为纵扭复合振动，使磨粒轨迹更复杂，提高加工质量。并且斜槽比直槽面积更大，散 热效果更好，更有利于降低磨削区域的温度。在辅助内层磨环70下端周向开有等间隔的内层磨环排屑槽73，方便散热与排屑。
外层磨环30上有四个均布的外层磨环通水孔33，其位置与外层磨环30二节径时的节径位置重合。图2为外层磨环的模态分析图，外层磨环在工作频率范围内有节圆式模态和节径式模态，以二节径模态为例，二节径环绕轴向均布。此时，外层磨环通水孔33既能使磨削液进入辅助内层磨环70，同时起到减少无效振动引起的能量损失以及砂轮减重的作用。
外层磨环30的中心锥孔31在与连接锥柄的锥面配合时定心准确方便，能够使外层磨环30与主轴有较好的同轴度；锥面连接更为紧密，在传递超声振动时能减小能量的损失，从而减小热量的产生，提高加工的效率；并且锥面连接在超声振动过程中具有自锁性，加工更安全。
如图3～5，连接锥柄20为由同轴的圆柱柄部和锥柄部构成的台阶轴。圆柱柄部用于与弹簧夹头连接，可快速装夹到超声刀柄上；在圆柱柄部上有一段外螺纹，用以连接退刀螺母10。锥柄部有一段锥螺纹，锥螺纹上端有一个工艺槽22，槽宽为2mm，深度为1mm；工艺槽22既起到退刀槽的作用，并且当外层磨环与连接锥柄20配合后，用螺母40将外层磨环30紧固在锥面上，螺母40与外层磨环30接触面所在平面恰好经过所述工艺槽22，起到隔振和减少摩擦的作用，如图6；连接锥柄20上加工螺纹孔21，用以与螺钉90连接，紧固辅助内层磨环70。
如图7～8，连接法兰50有不同形式可选。如图2，分析外层磨环30在工作频率下的模态，当模态为节圆式时，采用图7中节圆式连接法兰；当模态为二节径式时，采用图7中二节径式连接法兰。
a.节圆式连接法兰的内环面是一个锥面51，即中心锥形通孔，锥角为45°～90°。所述节圆式连接法兰包括法兰端面和位于所述法兰端面下端的环形夹持部；所述法兰端面具有与所述中心锥形通孔同轴的环槽53，所述环槽53沿所述节圆式轴向延伸至所述夹持部且将所述法兰端面分隔成法兰内环端面54和法兰外环端面55，法兰内环端面54比法兰外环端面55低0.2～0.5mm，保证锥面变形时法兰内环端面54有足够的运动空间。所述环形夹持部具有延伸至法兰内环端面54的中心锥形通孔，所述环形夹持部周向均匀设置有多个直槽52，所述直槽52的延伸方向与所述节圆连接法兰的轴向平行且槽口位于所述环形夹持部的下端面；所述直槽52和所述环槽53，用以减弱所述节圆连接法兰刚度，增加其变形 能力。
b.二节径式连接法兰比节圆式连接法兰多四个工艺隔离槽56，四个工艺隔离槽56绕轴向均布，与外层磨环30节径位置对应；工艺隔离槽56为扇形，深度为0.1mm～3mm，圆心角为0°～90°。
所述法兰外环端面55与所述环形夹持部外壁之间设有圆角57，所述圆角57下端比所述环槽53槽底低1mm以上，保证超声能量的传递。
所述辅助内层磨环70上侧外壁71与中心锥形通孔锥面配合层磨环，安装时将这两个面配合，即可对辅助内层磨环70进行定位；用垫片80和螺钉90将辅助内层磨环70紧固在连接锥柄20上；随着紧固力的增加，辅助内层磨环70上侧外壁71对连接法兰50的压力增加，连接法兰50变形，中心锥形通孔向外扩张，辅助内层磨环70沿中心锥形通孔上滑，实现辅助内层磨环70的高度调节；锥面接触时，超声能量的传递效率高，解决了螺纹连接时辅助内层磨环70超声振动不良的问题。辅助内层磨环70上开有4个通水孔72，使磨削液能进入内层磨环腔74，进而进入磨削区域；在辅助内层磨环70下端面周向开有内层磨环排屑槽73，方便散热与排屑，并丰富辅助内层磨环70的振型。
所述辅助内层磨环70下侧外壁设有环形凸起75，所述环形凸起75的上端面与内层磨环腔74的圆柱形腔77下端位于同一平面内，所述环形凸起75的周向设有与内层磨环排屑槽73连通的竖直槽；
所述辅助内层磨环70上侧外壁71与所述环形凸起75上端面之间设有退刀槽76。
如图6，退刀螺母10中间有一段导向孔11和一段内螺纹。安装时退刀螺母10的内螺纹与连接锥柄20上的外螺纹配合，导向孔11与连接锥柄20的圆柱柄部小间隙配合。退刀时旋转退刀螺母10，即可将因锥面配合自锁的外层磨环30顶开，方便砂轮更换。
实施例2
如图9-图14所述，一种用于超声加工的组合砂轮，其与实施例1中的用于超声加工的组合砂轮的区别特征为所述内层振动单元为主动散热盘100，所述主动散热盘100包括盘体101，所述盘体101上端中部具有圆柱形凸起102和多个位于所述圆柱形凸起102周向外侧的主动散热盘通水孔103，所述圆柱形凸起102下端具有容纳螺钉90头部的凹槽，所述圆柱形凸起102上端具有穿过所述凹槽槽底的所述中心孔；所述主动散热盘通水孔103外侧的所述盘体101上设 有与所述盘体101同轴的环形凸起104，所述环形凸起104的外壁构成与中心锥形通孔锥面配合的锥面；所述环形凸起104的外壁与所述盘体101之间设有主动散热盘退刀槽105。
最后应说明的是：以上各实施例仅用以说明本发明的技术方案，而非对其限制；尽管参照前述各实施例对本发明进行了详细的说明，本领域的普通技术人员应当理解：其依然可以对前述各实施例所记载的技术方案进行修改，或者对其中部分或者全部技术特征进行等同替换；而这些修改或者替换，并不使相应技术方案的本质脱离本发明各实施例技术方案的范围。

Claims (10)

  1. 一种用于超声加工的组合砂轮，其特征在于，包括：
    外层磨环，其上端具有中心锥孔和多个位于中心锥孔周向外侧的外层磨环通水孔，其下端具有与中心锥孔和外层磨环通水孔连通且下端敞开的外层磨环腔，与外层磨环腔所对应的外层磨环外壁具有多个与外层磨环腔连通的外层磨环斜槽，其中，外层磨环斜槽的槽口位于外层磨环下端面；
    连接锥柄，其下端具有由中心锥孔伸入至外层磨环腔且与中心锥孔锥面配合的锥柄部，所述锥柄部位于外层磨环腔内的锥段外壁螺纹连接有锥形或圆形螺母，所述螺母上端面与外层磨环腔上端内壁贴合；
    连接法兰，其位于锥柄部外侧且固定在外层磨环腔上端内壁上，其具有中心锥形通孔；
    以及，内层振动单元，其具有与中心锥形通孔锥面配合的锥面和通过螺钉与连接锥柄连接的中心孔。
  2. 根据权利要求1所述的用于超声加工的组合砂轮，其特征在于，所述外层磨环斜槽以所述外层磨环的轴线为轴均匀分布，且所述外层磨环斜槽的倾斜角度为0°～90°，宽度为1～10mm，槽深与槽宽比值为1～10。
  3. 根据权利要求1所述的用于超声加工的组合砂轮，其特征在于，所述连接锥柄为由同轴的圆柱柄部和锥柄部构成的台阶轴，所述圆柱柄部位于所述锥柄部上端且用于与超声刀柄连接；
    所述圆柱柄部外壁设有一段与退刀螺母连接的外螺纹；
    所述锥柄部位于外层磨环腔内的锥段外壁具有工艺槽；
    外层磨环与连接锥柄杆配合后，所述工艺槽上部位于中心锥孔内，所述工艺槽下部位于所述外层磨环腔内。
  4. 根据权利要求1所述的用于超声加工的组合砂轮，其特征在于，所述连接法兰包括法兰端面和位于所述法兰端面下端的环形夹持部；
    所述法兰端面具有与所述中心锥形通孔同轴的环槽，所述环槽沿所述连接法兰轴向延伸至所述环形夹持部且将所述法兰端面分隔成法兰内环端面和法兰外环端面，法兰内环端面比法兰外环端面低；
    所述环形夹持部具有延伸至法兰内环端面的中心锥形通孔，所述环形夹持部周向均匀设置有多个直槽，所述直槽的延伸方向与所述连接法兰的轴向平行 且槽口位于所述环形夹持部的下端面；
    所述夹持部锥孔的锥角为45°～90°。
  5. 根据权利要求4所述的用于超声加工的组合砂轮，其特征在于，所述法兰外环端面周向均匀设置有多个工艺隔离槽，且工艺隔离槽与所述外层磨环节径模态的节径位置对应；
    所述工艺隔离槽呈扇形，深度为0.1mm～3mm，圆心角为0°～90°。
  6. 根据权利要求4或5所述的用于超声加工的组合砂轮，其特征在于，所述法兰外环端面与所述环形夹持部外壁之间设有圆角，所述圆角下端比所述环槽槽底低1mm以上。
  7. 根据权利要求3所述的用于超声加工的组合砂轮，其特征在于，所述退刀螺母具有与所述圆柱柄部间隙配合的导向孔和与所述外螺纹配合的内螺纹。
  8. 根据权利要求1所述的用于超声加工的组合砂轮，其特征在于，所述内层振动单元为主动散热盘，所述主动散热盘包括盘体，所述盘体具有所述中心孔和多个位于所述中心孔周向外侧的主动散热盘通水孔；所述主动散热盘通水孔外侧的所述盘体上设有与所述盘体同轴的环形凸起，所述环形凸起的外壁构成与中心锥形通孔锥面配合的锥面；所述环形凸起的外壁与所述盘体之间设有主动散热盘退刀槽。
  9. 根据权利要求1所述的用于超声加工的组合砂轮，其特征在于，所述内层振动单元为辅助内层磨环，其上端具有所述中心孔和多个位于所述中心孔周向外侧的内层磨环通水孔，其下端具有与所述中心孔和内层磨环通水孔连通的内层磨环腔，所述辅助内层磨环上侧外壁构成与中心锥形通孔锥面配合的锥面，所述辅助内层磨环下端面具有多个内层磨环排屑槽；
    所述辅助内层磨环下侧外壁设有环形凸起，所述环形凸起的上端面与内层磨环腔的圆柱形腔下端位于同一平面内，所述环形凸起的周向设有与内层磨环排屑槽连通的竖直槽；
    所述辅助内层磨环上侧外壁与所述环形凸起上端面之间设有退刀槽。
  10. 一种用于超声加工的组合砂轮的设计方法，其特征在于具有如下步骤：
    由加工要求，确定组合砂轮的振动模态，当需要较大振幅时，外层磨环选择节圆模态，当需要较小的振幅时外层磨环选择节径模态；
    根据已确定的工作模态，设计外层磨环尺寸，使其在工作频率下实现所需模态；根据外层磨环的尺寸确定内层振动单元的尺寸，使其能够装入外层磨环 腔内且有合适的轴向调整量；
    根据内层振动单元和外层磨环的尺寸确定连接锥柄的尺寸，保证内层振动单元和外层磨环连接后外层磨环与锥柄接触处是超声波长的节点位置，且内层振动单元有合适的轴向调整量；
    确定外层磨环通水孔位置：外层磨环通水孔位置与外层磨环节径模态时的节径位置重合；
    根据外层磨环工作模态设计连接法兰：连接法兰可分为节圆式与节径式，分别适用于外层磨环的节圆模态和节径模态；节圆式连接法兰内环直径大于外层磨环节圆直径；节径式连接法兰的端面在对应外层磨环节径处开隔离槽；
    将设计完成的各零部件装配，即得到用于超声加工的组合砂轮。
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