Design of ultrasonic machining device for thin-wall cylinder of air compressor

An ultrasonic machining device for thin-wall cylinder was designed and manufactured in order to reduce the thermal and force deformations during machining the surface of thin-wall cylinder,and improve the dimension and shape precision.The device comprises of ultrasonic generator,ultrasonic energy converter,ultrasonic horn and ultrasonic machining tool.The ultrasonic generator transforms AC(220 V、50 Hz) to the electronic oscillator energy in ultrasonic frequency,which is transformed to the mechanical energy by the ultrasonic energy converter.The vibration amplitude of the ultrasonic energy converter is magnified and transferred to the ultrasonic machining tool by the ultrasonic horn.The mechanism tool machines the thin-wall cylinder.Analysis on the mechanism of machining the thin-wall cylinder shows that the ultrasonic machining can reduce the thermal deformation force deformations.The vibration mode analysis shows that the intrinsic frequency is much lower than the ultrasonic frequency.Finally,a thin-wall cylinder with a diameter of 90 mm was machined by ultrasonic machining.The test results showed that the dimension error and shape error were decreased during the ultrasonic machining.