IMPROVING THE MANUFACTURING EFFICIENCY OF NON-RIGID PARTS BY INTRODUCING THE ENERGY OF MODULATED ULTRASONIC VIBRATIONS INTO THE SHAPING ZONE

The use of ultrasonic dimensional technologies to reduce technological residual stresses occuring under machining of non-rigid blanks in parts made of alloys with a low melting point is one of the most effective methods for manufacturing structurally complex parts. The main methods of using modulated ultrasonic vibrations (UsV) and their advantages when introduced into the machining zone during milling operations are viewed. Special attention is paid to the use of various types of UsV modulation to increase the efficiency of reducing technological residual stresses by involving dislocation segments of different lengths in the relaxation process when machining thin-walled non-rigid aluminum alloy blanks. The technological residual stresses were evaluated using the Seton-ARM measuring and computing complex. Phase changes in the surface layer of aluminum parts of the Rikor–7 X-ray measuring complex. The data obtained was processed on a computer using the MD-10 program. The UsV modulation was carried out using an original installation that includes a ultrasonic generator, a PC that generates a modulation signal into two channels: on the first channel, a sinusoidal one, on the second, a sinusoidal, square or triangular one with a phase offset of 0 or 90 degrees. Studies measuring the positions of the treated surfaces of thin-walled parts using the Renishaw OMP40 contact sensor have shown that their twisted effect decreases by 30...40%. There was no significant difference in the results of processing workpieces made of deformable aluminum alloys D16 and AK6.

aluminum alloys, technological residual stresses, phase composition, ultrasound, modulation, blank, non-rigid part, milling