JP2006205140A - Ultrasonic machining apparatus - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide an ultrasonic machining apparatus which gives an approximately even ultrasonic vibration to a large tool so as to enhance the machining rate and accuracy even when a work piece is of a large form. <P>SOLUTION: An ultrasonic alternative electric voltage having a resonant frequency of each of five bolted Langevin type ultrasonic transducers 2a, 2b, 2c, 2d and 2e is applied thereto from each of ultrasonic driver circuits 14a, 14b, 14c, 14d and 14e respectively. A vibration generated by the bolted Langevin type ultrasonic transducer 2 is propagated to a cone 7 and then to a tool 8. <P>COPYRIGHT: (C)2006,JPO&NCIPI

Description

  The present invention uses ultrasonic vibration to produce a relatively large area of abrasive grains, cutting, plastic processing, cutting, metal bonding, plastic bonding, metal molding and plastic molding. The present invention relates to a processing apparatus.

Applications that use ultrasonic energy are called dynamic ultrasonic applications, and those that use ultrasonic waves with large vibration amplitude and vibration speed are particularly called strong ultrasonic applications.
The application of high-intensity ultrasound is described in detail in “Ultrasonic Handbook” (Maruzen Co., Ltd., published in 1999), pages 661-697.

For example, it is used for processing and processing a substance by utilizing a large acceleration which is a characteristic of ultrasonic waves. This field is abrasive processing, cutting processing, plastic processing, and cutting processing.
Further, in a solid, when powerful ultrasonic waves propagate, there is a remarkable heat generation effect due to generation of vibration stress. This effect combined with heat generated by friction is used for joining metals, joining thermoplastics, and crosslinking polymer materials.

  In order to generate a powerful ultrasonic wave, a powerful ultrasonic wave generation source is required, and a bolted Langevin ultrasonic vibrator is usually used. An example of this is the ultrasonic welding machine shown in FIG. The cone for propagating ultrasonic vibrations to the tool is small compared to the tool. This will be described with reference to FIGS. 2 and 3 for further explanation. In FIG. 2, since the area of the surface of the tool 8 that contacts the cone is larger than that of the cone, slits 13a and 13b are provided in order to disperse the ultrasonic vibration in the tool 8 as uniformly as possible. However, in reality, the ultrasonic vibration in the portion in contact with the cone inevitably increases. Further, when using a large tool 8 as shown in FIG. 3, the effects of the slits 13a, 13b, 13c, and 13d are also reduced, and a large difference in vibration displacement occurs between the portion just below and the end of the cone.

  FIG. 4 is a perspective view showing a state where the cone connected to the bolted Langevin ultrasonic vibrator is further attached to the tool, but the ultrasonic vibration is highly straight, and the vibration of the portion a surrounded by a circle is large. The vibrations in the portions b and c are reduced.

Even when the tool is increased in size, the workpiece is often ultrasonically processed using only one bolted Langevin ultrasonic transducer. For this reason, when the size of the tool increases, the contact area between the tool and the workpiece increases, so the ultrasonic vibration energy per unit area decreases in proportion to the contact area. As a result, there arises a problem that the processing speed becomes low, the power density becomes too low, and processing cannot be performed. Furthermore, although a contrivance is made so that ultrasonic vibration is uniformly applied to the workpiece by providing slits in the tool, there is a problem that vibration distribution occurs.
The objective of this invention is providing the ultrasonic processing apparatus which eliminates the above-mentioned problem.

  The present invention provides an ultrasonic processing apparatus that has two or more bolted Langevin type ultrasonic transducers and performs processing using ultrasonic vibration, and has the same number of ultrasonic drive power supplies as bolted Langevin type ultrasonic transducers. The ultrasonic processing apparatus is provided.

  In the above-described configuration, the ultrasonic machining apparatus applies an ultrasonic AC voltage having a resonance frequency of each of two or more bolted Langevin type ultrasonic transducers.

  The ultrasonic processing apparatus is intended for welding.

  The ultrasonic processing apparatus is intended for pressing.

  The ultrasonic processing apparatus is intended for cutting.

  The ultrasonic processing apparatus is intended to process using abrasive grains.

Since the ultrasonic processing apparatus of the present invention can excite ultrasonic vibrations having a substantially uniform size on a tool, even if the object to be processed is increased in size, ultrasonic processing with a substantially uniform size is possible.
Further, even if the tool is enlarged, the processing speed of the processing object can be maintained without being substantially affected by the size of the tool.

  The present invention will be described with reference to the accompanying drawings. FIG. 5 is a perspective view showing a tool of the ultrasonic welder having the first configuration of the present invention and a bolted Langevin type ultrasonic transducer connected thereto.

  In order to simplify the drawing, only the tool 8, the cone 7, the bolted Langevin type ultrasonic transducers 2a, 2b, 2c, 2d and 2e and the ultrasonic drive circuits 14a, 14b, 14c, 14d and 14e are shown. Five ultrasonic drive circuits 14a, 14b, 14c, 14d, so that the ultrasonic alternating voltages of the respective resonance frequencies of the five bolt-clamped Langevin type ultrasonic transducers 2a, 2b, 2c, 2d, 2e can be applied. 14e is connected. As shown in FIG. 7, the actual configuration is such that a support plate is inserted in the center of two piezoelectric ceramics of a bolted Langevin type ultrasonic transducer and connected to an air cylinder.

    A similar conventional configuration will be described with reference to FIG. Similarly, only the tool 8, the cone 7, the bolted Langevin type ultrasonic transducer 2 and the ultrasonic drive circuit 14 are shown. An ultrasonic drive circuit 14 is connected to one bolted Langevin type ultrasonic transducer 2 so that an ultrasonic alternating voltage of the resonance frequency can be applied. As shown in FIG. 1, an integrated cone and vibrator are connected to an air cylinder via a cone flange. The tool is a fraction of the area of the tool at the interface with the cone. In such a configuration, since the ultrasonic vibration has high straightness, the vibration of the portion a in FIG. 4 is the largest. The vibrations of the ends b and c are smaller than those of the portion a. Therefore, slits 13a, 13b, 13c, and 13d are provided to aim at uniformizing the vibrations of a, b, and c.

  On the other hand, the configuration of the present invention is such that the ultrasonic drive circuits 14a, 14b, 14c, 14d, and 14e of FIG. 5 to the AC voltages of the resonance frequencies of the bolted Langevin type ultrasonic transducers 2a, 2b, 2c, 2d and 2e. Is applied. In this way, when the AC voltage of the resonance frequency of each bolted Langevin type ultrasonic transducer 2a, 2b, 2c, 2d, 2e is applied, each bolted Langevin type ultrasonic transducer 2a, 2b, 2c, 2d, Since the ultrasonic vibration of 2e goes straight to the positions of circles a, b, c, d, and e below the one-dot chain line, the vibrations at the positions of a, b, c, d, and e are almost uniform. Although the tool of FIG. 5 is not provided with a slit, it may be desirable to provide a slit depending on the shape and material of the tool.

  Next, the ultrasonic drive circuit 14 will be described with reference to FIG. The ultrasonic oscillation circuit 14 applies a sine wave voltage having a frequency corresponding to the resonance frequency of the bolted Langevin type ultrasonic transducer 2. The vibrator in FIG. 12 is a bolted Langevin type ultrasonic vibrator 2.

  A PLL (Phase-locked-loop) circuit shown in FIG. 12 generates a rectangular wave voltage having a frequency corresponding to the resonance frequency of the bolted Langevin type ultrasonic transducer 2. This rectangular wave voltage is amplified by the driver circuit, and then the electric power factor is improved by the matching circuit, and is applied to the bolted Langevin type ultrasonic transducer 2 as a sine wave voltage.

  The voltage / current detection circuit provided between the matching circuit and the bolt-clamped Langevin type ultrasonic transducer 2 detects an AC voltage, an AC current, and a phase thereof applied to the bolt-clamped Langevin type ultrasonic transducer. To do.

  The power control unit calculates the power applied to the bolted Langevin type ultrasonic transducer based on the AC voltage and AC current detected by the voltage / current detection circuit and their phases. The power control unit controls the power amplification factor of the driver circuit based on the calculated power value so that a predetermined amount of power is applied to the bolted Langevin type ultrasonic transducer.

  On the other hand, the phase circuit inputs a signal obtained by converting the current flowing in the bolt-clamped Langevin type ultrasonic transducer from the voltage / current detection circuit into current-voltage, and the control frequency of the frequency control block is the bolt-clamped Langevin type ultrasonic wave The signal is phase-shifted so as to have the resonance frequency of the vibrator, and then a voltage signal converted into a pulse voltage is output to the PLL circuit.

  The PLL circuit controls the frequency of the rectangular wave voltage output from the PLL circuit so that the phase of the pulsed voltage output from the phase circuit matches the phase of the rectangular wave voltage output from the PLL circuit. By such control, even when the resonance frequency of the bolted Langevin type ultrasonic transducer is slightly changed due to a change in the environmental temperature, for example, the resonance frequency of the bolted Langevin type ultrasonic transducer is always changed. It is possible to apply an alternating voltage with a frequency corresponding to.

  However, when the bolted Langevin type ultrasonic transducers 2a, 2b, 2c, 2d, and 2e are connected in parallel and a voltage of the same frequency is applied from one ultrasonic driving circuit, the vibrations of each other are synthesized. Thus, the vibration at the position of the circle c in the center of the one-dot chain line is inevitably increased.

FIG. 6 is a plan view of an ultrasonic welder incorporating the tool, cone, bolted Langevin type ultrasonic transducer and ultrasonic drive circuit shown in FIG. 5, and FIG. 7 is a side view thereof. Here, the ultrasonic drive circuit is not shown in order to simplify the drawing.

There is a stainless steel frame 9 attached to the rod 11 of the air cylinder 10 attached to the base 12. Then, bolted Langevin type ultrasonic transducers 2a, 2b, 2c, 2d and 2e having a common support plate 6 are joined to the stainless steel frame base 9 by bolts (not shown). The bolted Langevin type ultrasonic transducer 2 includes an aluminum alloy front mass 3, an aluminum alloy rear mass 4, a piezoelectric ceramic 5, and five bolted Langevin type ultrasonic transducers 2a, 2b, 2c, 2d, and 2e. A common stainless steel support plate 6 is tightened with bolts and nuts. Here, bolts and nuts are not shown for convenience of drawing. Each cone 7 is joined to each bolted Langevin type ultrasonic transducer 2 with a bolt. Further, the tip of the cone 7 and the tool 8 are joined by a bolt (not shown).

  Next, an operation method of the ultrasonic welder which is the ultrasonic processing machine 1 will be described. First, AC voltages having respective resonance frequencies of bolted Langevin type ultrasonic transducers 2a, 2b, 2c, 2d, and 2e are applied from five ultrasonic drive circuits (not shown). The ultrasonic vibration of the bolted Langevin type ultrasonic vibrator 2 propagates to the cone 7 and the tool. As described above, the vibrations at positions a, b, c, d, and e on the alternate long and short dash line of the tool tip are substantially uniform. Then, the air cylinder 10 is operated to move the rod 11 downward.

  The ultrasonic vibration propagates to a workpiece (not shown), and the workpiece is welded or welded. Even with a large workpiece that has been difficult in the past, the vibrations at the positions of a dashed-dotted lines a, b, c, d, and e of the tool tip are almost uniform, so that uniform welding can be achieved.

  The above-described configuration of the present invention can be used almost as it is for an ultrasonic machining apparatus used for cutting, plastic working, cutting, metal joining, metal forming, and plastic forming.

  Next, an ultrasonic abrasive processing apparatus that is an ultrasonic processing machine having a second configuration of the present invention will be described. First, a conventional ultrasonic abrasive machining apparatus will be described.

  The ultrasonic abrasive machining apparatus of FIG. 8 uses a magnetostrictive transducer as an ultrasonic vibration source. The vibration of the magnetostrictive transducer propagates to the cone and further propagates to the horn and the tool. Abrasive grains are interposed between the workpiece and the tool, the abrasive grains are vibrated by the vibration of the tool, and the workpiece is subjected to abrasive machining by the movement of the abrasive grains.

Details of an example of this tool are shown in FIG. A cemented carbide tool is attached to the tip of the horn by welding or brazing. The tool is smaller than the area of the horn tip.
In this way, it is easy to attach a tool smaller than the area of the tip of one horn and grind the workpiece, but it is more than twice as large as the area of the tip of one horn. In some cases, it is difficult to give uniform vibration to the tool.

  On the other hand, the ultrasonic abrasive grain processing apparatus of the second configuration of the present invention is optimal for a tool having a large processing area. FIG. 10 shows only the bolted Langevin type ultrasonic transducers 2a, 2b, 2c, and 2d and the tool 8 in the ultrasonic abrasive processing apparatus. The tool 8 and the bolted Langevin type ultrasonic transducers 2a, 2b, 2c, and 2d are coupled with a bolt (not shown). The tool 8 is provided with 16 square holes. For example, a glass plate or the like is punched into the shape of the hole by abrasive processing.

  Four ultrasonic drive circuits (not shown) are connected to each bolted Langevin type ultrasonic transducer 2a, 2b, 2c, 2d. An AC voltage having a resonance frequency of each of the bolted Langevin type ultrasonic transducers 2a, 2b, 2c, and 2d is applied from the respective ultrasonic drive circuits to the bolted Langevin type ultrasonic transducers 2a, 2b, 2c, and 2d. Thus, when the alternating voltage of the resonance frequency of each bolting Langevin type ultrasonic transducer 2a, 2b, 2c, 2d is applied, the ultrasonic wave of each bolting Langevin type ultrasonic transducer 2a, 2b, 2c, 2d is applied. Since the vibration goes straight to the position immediately below, the vibration becomes almost uniform if a plurality of bolted Langevin type ultrasonic transducers are arranged so as to be suitable for the two-dimensional shape.

  However, even in the same configuration, when bolted Langevin type ultrasonic transducers 2a, 2b, 2c and 2d are connected in parallel and a single frequency drive voltage is applied from one ultrasonic drive circuit, the mutual vibrations are synthesized. The vibration at the center position will inevitably increase.

  FIG. 11 shows a side view of an ultrasonic abrasive processing apparatus which is the ultrasonic processing apparatus 1 incorporating the tool, bolted Langevin type ultrasonic vibrator and ultrasonic drive circuit shown in FIG. Here, the four ultrasonic drive circuits are not shown in order to simplify the drawing.

  Bolt-clamped Langevin type ultrasonic transducers 2a, 2b, 2c, 2d having a common support plate 6 are attached to a stainless steel frame base 9 attached to a rod 11 of an air cylinder (not shown) by bolts (not shown). The bolted Langevin type ultrasonic transducer 2 includes a front mass 3 made of aluminum alloy, a rear mass 4 made of aluminum alloy, a piezoelectric ceramic 5, and a stainless steel support plate 6 common to the four bolted Langevin type ultrasonic transducers. It is manufactured by tightening with bolts and nuts. Here, bolts and nuts are not shown for convenience of drawing. Then, the tool 8 is joined to the bolted Langevin type ultrasonic vibrator 2 with a bolt.

  Next, the operation method of this ultrasonic abrasive grain processing apparatus will be described. First, AC voltages having respective resonance frequencies of the bolted Langevin type ultrasonic transducers 2a, 2b, 2c, and 2d are applied from four ultrasonic drive circuits (not shown). The ultrasonic vibration of the bolted Langevin type ultrasonic vibrator 2 propagates to the tool 8. As described above, the vibration at the tip of the tool 8 becomes substantially uniform. Then, the air cylinder is operated to move the rod 11 downward.

  The ultrasonic vibration propagates to the workpiece 13 which is a glass plate placed on the processing table 14, and the workpiece 13 is subjected to abrasive grain processing. Even with a large workpiece, which has been difficult in the past, the vibration at the tip of the tool 8 is almost uniform, so uniform abrasive machining can be performed.

  The above-described configuration of the present invention can be used almost as it is for an ultrasonic machining apparatus used for cutting, plastic working, cutting, metal joining, metal forming, and plastic forming.

  The ultrasonic processing apparatus of the present invention can be used for welding and molding of plastics and metals, abrasive processing of difficult-to-process materials, and the like.

  It is a side view which shows the structure of the conventional ultrasonic welding machine.   It is a perspective view which shows the tool used for the conventional ultrasonic welding machine.   It is a perspective view which shows another tool used for the conventional ultrasonic welding machine.   It is a perspective view which shows the structure which connected the tool, cone, and Langevin type vibrator | oscillator used for the conventional ultrasonic welding machine.   It is a perspective view which shows the structure of the tool connected to the ultrasonic welding machine of the 1st structure of this invention, a cone, and a Langevin type ultrasonic transducer | vibrator.   It is a top view which shows the ultrasonic welding machine of the 1st structure of this invention.   It is a side view which shows the ultrasonic welding machine of the 1st structure of this invention.   It is a figure which shows the structure of the conventional ultrasonic abrasive grain processing apparatus.   It is a perspective view which shows the horn and tool used for the conventional ultrasonic abrasive grain processing apparatus.   It is a perspective view which shows the structure which connected the tool and Langevin type vibrator of the ultrasonic abrasive grain processing apparatus of the 2nd structure of this invention.   It is a perspective view which shows the ultrasonic abrasive grain processing apparatus of the 2nd structure of this invention.   It is a figure explaining an ultrasonic drive circuit.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 Ultrasonic processing machine 2 Bolt tightening Langevin type ultrasonic transducer 3 Front mass 4 Rear mass 5 Piezoelectric ceramic 6 Support plate 7 Cone 8 Tool 9 Frame base 10 Air cylinder 11 Rod 12 Base base 13 Slit 14 Ultrasonic drive circuit 15 Workpiece Item 16 Processing table

Claims (6)

In an ultrasonic processing apparatus that has two or more bolted Langevin type ultrasonic vibrators and performs processing using ultrasonic vibration, it has the same number of drive power sources as bolted Langevin type ultrasonic vibrators. Ultrasonic machining equipment characterized. The ultrasonic processing apparatus according to claim 1, wherein an ultrasonic alternating voltage having a resonance frequency of each of the two or more bolted Langevin type ultrasonic transducers is applied. The ultrasonic processing apparatus according to claim 1, wherein the ultrasonic processing apparatus is a welding apparatus. The ultrasonic processing apparatus according to claim 1, wherein the ultrasonic processing apparatus is a press apparatus. The ultrasonic processing apparatus according to claim 1, wherein the ultrasonic processing apparatus is a cutting apparatus. The ultrasonic processing apparatus according to claim 1, wherein the ultrasonic processing apparatus is an apparatus that performs processing using abrasive grains.

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