目的 针对振动辅助加工装置输出位移波动的问题,以二维非共振直驱抛光工具系统为研究对象,通过优化压电陶瓷驱动器的装配预紧力,提升其振动输出性能。方法 基于MCM法和数值模拟完成装置的结构设计,并通过振动辅助装置性能测试平台,评估其振动性能。测试压电陶瓷驱动器在不同输入电压下,外部预紧力变化对振动辅助加工装置输出位移的影响规律。结果 实验结果表明,压电陶瓷驱动器的外部预紧力对振动装置的输出位移具有规律性调控作用,预紧力在60~180 N范围内输出位移整体呈现先升后降的趋势,并于90 N时输出位移达到最优,且该最优值在30~150 V电压范围内具有普适性。利用施加最优装配预紧力的二维振动辅助抛光装置对铝合金表面进行抛光,经35 min抛光,工件表面粗糙度Sa由0.262 μm降至0.098 μm。结论 通过预紧力调控,可在不改变驱动电压的条件下,有效调节输出位移,为振动辅助加工的主动控制与性能优化提供了新途径,增强系统对不同加工工况的适应能力,以此提高振动辅助加工系统的可靠性,为振动辅助加工的产业化探索提供一定的支撑。
Abstract
In response to the output displacement fluctuation of vibration-assisted machining devices, the work aims to select a two-dimensional non-resonant direct-drive polishing tool system as the research object to improve the vibration output performance of the machining system by optimizing the assembly preload of piezoelectric ceramic actuators. Piezoelectric ceramic actuators are core excitation components for ultra-precision vibration-assisted machining due to their high positioning accuracy, fast dynamic response and compact structure. Nevertheless, mismatched assembly preload is a key factor causing unstable vibration output and displacement fluctuation of piezoelectric driving systems. Most current researches focus on structural optimization and driving signal modulation of vibration devices, while few studies quantitatively explore the coupling effect between assembly preload and output performance of two-dimensional non-resonant polishing systems. Therefore, this work optimizes the preload of piezoelectric actuators to eliminate displacement fluctuation and improve the overall vibration output stability of the polishing tool system.
The structural design of the vibration-assisted machining device is completed by combining the Matrix Compliance Model (MCM) and numerical simulation. The Matrix Compliance Model is adopted to analyze the static and dynamic mechanical characteristics of the flexible hinge and vibration transmission structure of the system, and numerical simulation is conducted to predict the stress distribution of piezoelectric stacks actuators and vibration output characteristics under different preload conditions. A dedicated performance test platform for the vibration-assisted device was built to test and evaluate the decoupling performance, natural frequency, step response, hysteresis characteristics, and maximum displacement of the prototype. In the experiment, the input driving voltage of the piezoelectric ceramic actuators was set in the range of 30 to 150 V, with the preload ranging from 60 to 180 N. The effect of external preload variation on the output displacement of the device under different input voltages was tested and analyzed. Finally, comparative polishing experiments on aluminum alloy workpieces were carried out with the optimal preload parameter, and the surface roughness parameter Sa was measured to verify the practical machining performance of the optimized system.
Experimental results reveal that the external preload applied on piezoelectric ceramic actuators has a regular regulating effect on the output displacement of the vibration device. Within the preload range of 60 to 180 N, the output displacement presents an overall trend of increasing first and then decreasing. The maximum output displacement is obtained at the preload of 90 N, and this optimal preload value is universally applicable within the driving voltage range of 30 to 150 V. The aluminum alloy surface is polished using a two-dimensional vibration-assisted machining device under the optimal assembly preload. After 35 min of polishing, the workpiece surface roughness Sa decreases from 0.262 μm to 0.098 μm.
Without adjusting the driving voltage, the output displacement of the vibration-assisted machining system can be effectively regulated via preload optimization. This research provides a novel method for active control and performance optimization of vibration-assisted machining systems. It effectively enhances the working adaptability of the machining system to diverse machining conditions, improves the operation reliability of piezoelectric vibration machining equipment, and provides technical support for the engineering application and industrial promotion of vibration-assisted ultra-precision machining technology.
关键词
振动辅助 /
预紧力 /
二维振动 /
位移 /
压电陶瓷驱动器 /
抛光
Key words
vibration-assisted /
preload /
two-dimensional vibration /
displacement /
piezoelectric ceramic actuator /
polishing
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基金
吉林省重大科技专项（20230301004GX）
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