Abstract
Cavitation will occur in the process of power ultrasonic honing. To explore the influence of cavitation on the material surface processed, an ultrasonic honing cavitation orthogonal experiment is conducted and three indicators are analyzed, which are pits’ maximum diameter, surface erosion rate, and surface roughness and can represent the single bubble collapse strength, the whole cavitation strength, and the impact of cavitation on material surface quality, respectively. The results show that cavitation leads to micro-pits on material surface. The main factors influencing the pits’ maximum diameter are distance and amplitude in turn; meanwhile, the shorter distance and the greater amplitude result in the larger pits’ maximum diameter. The surface erosion rate is mainly affected by experiment time and distance in order. Amplitude has the greatest influence on the surface roughness. The sample surface roughness reduces and surface quality improves in the condition of distance of 5 mm, amplitude of 65%, and experiment time of 1/3 min. Therefore, cavitation effect can help to enhance the workpiece surface quality in power ultrasonic honing under certain conditions, and the experimental analysis results have reference significance to the actual processing of ultrasonic honing.
Highlights
Power ultrasonic honing machining technology is a kind of precision and ultra-precision grinding technology and widely used in 42MnCr52, 38CrMnA, sintered NdFeB, and other hard brittle and difficult-to-machine materials in the cylinder bore machining, with some advantages such as small honing force, low honing temperature, high honing efficiency, and high machining precision.[1]
Micro-jet forms when the cavitation bubble collapses and impacts toward material surface, and shock wave takes place when the bubble collapses to the minimum size and begins to rebound
This article first introduces the cavitation mechanism in ultrasonic honing, three parameters, that is, distance, amplitude, and experiment time are selected to carry on the cavitation orthogonal experiment of power ultrasonic honing, and investigates the effect of cavitation on material surface based on the range and variance analysis
Summary
Power ultrasonic honing machining technology is a kind of precision and ultra-precision grinding technology and widely used in 42MnCr52, 38CrMnA, sintered NdFeB, and other hard brittle and difficult-to-machine materials in the cylinder bore machining, with some advantages such as small honing force, low honing temperature, high honing efficiency, and high machining precision.[1]. Micro-jet forms when the cavitation bubble collapses and impacts toward material surface, and shock wave takes place when the bubble collapses to the minimum size and begins to rebound. This article first introduces the cavitation mechanism in ultrasonic honing, three parameters, that is, distance, amplitude, and experiment time are selected to carry on the cavitation orthogonal experiment of power ultrasonic honing, and investigates the effect of cavitation on material surface based on the range and variance analysis. Cavitation bubbles collapse under the action of ultrasonic vibration and honing pressure, releasing high-speed micro-jet and strong shock wave, which is very important for purifying honing environment, suppressing honing noise, and assisting material removal. In the whole ultrasonic honing process, there will be a large number of micro-jets impinging on the wall, which will have effect on the material surface. The aluminum sheet surface was cleaned with alcohol and data measurement was performed
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