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<p>At present, arc-shaped mortise grooves in titanium alloys are increasingly demanded in aerospace equipment manufacturing due to their superior load-bearing capacity and enhanced structural stability compared to straight or inclined grooves. However, conventional broaching methods are not suitable for the precise machining of such curved profiles, making form grinding one of the most promising techniques for the precision fabrication of arc-shaped mortise grooves. During the induction brazing process of form grinding tools, non-uniform temperature distribution frequently occurs, which negatively affects tool performance. In response to this challenge, the present study aims to optimize the structure of the induction coil used in the induction brazing process for form grinding tools specifically designed for arc-shaped mortise grooves. Through finite element simulation analysis, it was found that when the coil diameter is 2&#xa0;mm, the number of coil turns is 6, and the distance between the coil and the central axis of the substrate is 30&#xa0;mm, the maximum temperature difference during induction heating is relatively small, and the brazing temperature uniformity is good. Based on this, the coil structure was further optimized to adapt to the induction brazing processing of tools with complex surfaces. The final optimized induction coil structure achieved a temperature variance of only 740.12, with a temperature uniformity index reaching 0.507. During induction brazing, the maximum temperature difference on the tool surface was reduced to 77.2&#xa0;K, representing a 21.8% reduction compared to before optimization. Then, an ultrasonic vibration-assisted high-frequency induction brazing forming tool test was carried out. With the optimized induction coil, induction brazing forming tool with better brazing quality was obtained, which showed that the temperature distribution on the abnormal surface of forming tool had better uniformity during the processing of the optimized induction coil.</p>

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Induction coil optimization for ultrasonic-assisted high-frequency brazing of forming grinding tools

  • 期刊论文

  • 发表日期：

    2025年12月22日

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  • Ziang Liu,
  • Zihao Jiang,
  • Rong Wang,
  • Xiaofei Lei,
  • Biao Zhao,
  • Wenfeng Ding,
  • Xu Liu,
  • Tianfeng Wu

摘要

At present, arc-shaped mortise grooves in titanium alloys are increasingly demanded in aerospace equipment manufacturing due to their superior load-bearing capacity and enhanced structural stability compared to straight or inclined grooves. However, conventional broaching methods are not suitable for the precise machining of such curved profiles, making form grinding one of the most promising techniques for the precision fabrication of arc-shaped mortise grooves. During the induction brazing process of form grinding tools, non-uniform temperature distribution frequently occurs, which negatively affects tool performance. In response to this challenge, the present study aims to optimize the structure of the induction coil used in the induction brazing process for form grinding tools specifically designed for arc-shaped mortise grooves. Through finite element simulation analysis, it was found that when the coil diameter is 2 mm, the number of coil turns is 6, and the distance between the coil and the central axis of the substrate is 30 mm, the maximum temperature difference during induction heating is relatively small, and the brazing temperature uniformity is good. Based on this, the coil structure was further optimized to adapt to the induction brazing processing of tools with complex surfaces. The final optimized induction coil structure achieved a temperature variance of only 740.12, with a temperature uniformity index reaching 0.507. During induction brazing, the maximum temperature difference on the tool surface was reduced to 77.2 K, representing a 21.8% reduction compared to before optimization. Then, an ultrasonic vibration-assisted high-frequency induction brazing forming tool test was carried out. With the optimized induction coil, induction brazing forming tool with better brazing quality was obtained, which showed that the temperature distribution on the abnormal surface of forming tool had better uniformity during the processing of the optimized induction coil.