第一作者申昊男，博士生，1988年9月生

通信作者郁鼎文男，教授，1962年10月生

两级阶梯形变幅杆设计及优化

申昊，蔡万宠，郁鼎文

(清华大学机械工程学系，北京100084)

摘要：基于ANSYS workbench多目标驱动优化模块对两级阶梯形变幅杆进行优化设计。基于解析法设计两级阶梯形变幅杆，建立参数化变幅杆模型；在静力学分析基础上对变幅杆进行模态、谐响应分析。通过52个设计点仿真分析获得谐振频率、放大系数、最大应力与变幅杆结构尺寸关系，并优化变幅杆尺寸。研究表明，变幅杆谐振频率小于理论设计频率，振幅放大系数小于理论值，超声能量损耗较大。优化所得变幅杆的谐振频率接近理论设计频率，提高放大系数。为大功率、大振幅的超声变幅杆优化设计提供新的设计、优化思路。

关键词：阶梯形变幅杆；多目标驱动优化；放大系数；谐振频率；超声加工

基金项目：国家自然科学基金(51475260)；北京市科技项目(D131100002713003)

收稿日期：2014-06-03修改稿收到日期：2014-09-12

中图分类号:TG663

文献标志码：A

DOI:10.13465/j.cnki.jvs.2015.20.018

Abstract:A two-section ultrasonic stepped horn was designed and optimized using the multi-goal driven optimization method based on ANSYS workbench. Based on analytical method, the two-section ultrasonic stepped horn was designed and a parameterized model of the horn was established. In addition, the amplifying rate and resonant frequency of the horn were obtained by using static, modal and harmonic response analyses. A simulation with fifty-two design points selected was carried out, and the relationship between vibration parameters and sizes of the horn was obtained. Moreover, the sizes of the ultrasonic horn were optimized using the multi-goal driven optimization method. The results show that the real resonant frequency is lower than the theoretically designed frequency and the real amplifying rate of the horn inclines to be smaller than the theoretical one. Through optimization, the deviation between the real resonant frequency and theoretically designed frequency is reduced, and the amplifying rate is improved. The paper provides a new optimal design method of ultrasonic horn in high-power ultrasonic machining.

Design and optimization of two-section ultrasonic stepped horn

SHENHao,CAIWan-chong,YUDing-wen(Department of mechanical engineering, Tsinghua University, Beijing 100084, China)

Key words:two-section ultrasonic stepped horn; multi-goal driven optimization; amplifying rate; resonant frequency; ultrasonic machining

超声加工系统主要由超声波发生器、换能器及变幅杆等组成。变幅杆起放大换能器输出机械振动振幅、聚集超声振动能量及超声振动系统阻抗匹配等作用，其声学振动特性对整个超声加工装置均极其重要[1-2]。而减小变幅杆超声能量传递损失、提高放大系数已成超声振动系统研究热点。Amin等[3]将有限元方法用于超声变幅杆设计，优化变幅杆曲线形状、提高超声加工材料去除率。张可昕等[4]用有限元法设计带加工工具的复合变幅杆，分析刀具尺寸对变幅杆放大倍数、谐振长度影响，优化获得变幅杆最佳放大倍数及谐振长度。……