Research on the Influence of Cutting Condition on the Surface Microstruct ure of Ultra-thin Wall Parts in Ultrasonic Vibration Cutting

In many fields of high-tech industry the ultra-t hi n wall parts are employed. In this paper the experiments were carried out to dis cuss the surface microstructure of the camera’s guided drawtube by applying ult rasonic vibration cutting device to the traditional lathe. The influence rule of the cutting condition on the surface roughness was put forward, which was drawn by comparing the ultrasonic cutting with the common cutting by use of the cemen ted carbide tool and the polycrystalline diamond (PCD) tool. The test results sh owed that the ultrasonic cutting performs better than the common cutting in the same condition. According to the test results analyzing, the surface characteriz ation is influenced clearly by the rigidity of the acoustic system and the machi ne tool, as well the setting height of the tool tip. Otherwise, the dense regula r low frequency vibration ripples will be scraped on the machined surface. When the tool tip is set higher than the rotating center of the work piece by three t imes of the amplitude of ultrasonic vibration, the vibration ripples behave alig ht; they turn light and shade alternatively when the tool tip is lower than the rotating center of the work piece by three times of the amplitude of ultrasonic vibration. According to the test result analyzing, the following conclusions are put forward: 1) The surface roughness in ultrasonic cutting is better than that in common cutting. Under a one third critical cutting velocity, the value of th e surface roughness in ultrasonic cutting rise slightly along with the cutting v elocity, while in common cutting it decreases contrast to the cutting velocity; the curves of the surface roughness in ultrasonic cutting and common cutting see m to be alike, both increase along with the feed rate and the cutting depth, but the value in ultrasonic cutting is smaller in the same condition.2) The influen ce of the coolant on the surface roughness cannot be ignored. The kerosene can b e employed to improve the surface roughness in ultrasonic machining.3) In ultras onic cutting process of aluminum alloy ultra-thin wall work piece, the PCD tool performs better than the cemented carbide tools.4) The vibration ripples result from the not enough rigidity of the acoustic system and the improper setting he ight of the tool tip. The departure of the tool tip from the rotating center of the work piece to some extent causes the vibration ripples on the machined surfa ce.

Numerical analysis of flow-thermal coupling in micro-plasma welding pool of thin-wall part

The formed characteristics of thin-wall part is studied when it is in the process of MPAW. Finite element method is used to sinmlate the temperature field coupling flow field in the welding of thin-wall part. It is found that because of the obvious effect of heat accumution in cross-section, where the distribution of temperature field area presents trapezoidal inverted approximately in the molten pool and the non-molten pool area presents level. The surface tension, the electromagnetic force and buoyancy are considered for analyzing the effects on the fluid flow of welding-pool. It can be obtained that the surface tension is the main driving force in the welding pool, which is far greater than electromagnetic force and buoyancy.

Machining Deformation Prediction of Thin-Walled Part Based on Finite Element Analysis

For the problems of machining distortion and the low accepted product during milling process of aluminum alloy thin-walled part,this paper starts from the analysis of initial stress state in material preparation process,the change process of residual stress within aluminum alloy pre-stretching plate is researched,and the distribution law of residual stress is indirectly obtained by delamination measurement methods,so the effect of internal residual stress on machining distortion is considered before finite element simulation. Considering the coupling effects of residual stress,dynamic milling force and clamping force on machining distortion,a threedimensional dynamic finite element simulation model is established,and the whole cutting process is simulated from the blank material to finished product,a novel prediction method is proposed,which can availably predict the machining distortion accurately. The machining distortion state of the thin-walled part is achieved at different processing steps,the machining distortion of the thin-walled part is detected with three coordinate measuring machine tools,show that the simulation results are in good agreement with experimental data.

Inner and outer pressure forming of nickel based super-alloy thin-walled part with variable diameter sections

A novel forming method of nickel based super-alloy thin-walled part with variable diameter sections was proposed by using inner and outer pressure with the visco-elasto-plastic pressure-carrying medium at room temperature,and the principle of the method was provided.Experiments and FE simulations were carried out to analyze the deformation characteristics for the part with larger variable diameter ratio(35%).The results show that visco-elasto-plastic pressure-carrying medium can meet the requirements of the room-temperature deformation condition for nickel based super-alloy sheet.The inner and outer pressure forming with the visco-elasto-plastic pressure-carrying medium can meet the requirements of dimensional accuracy for the thin-walled part with variable diameter sections.The thinning of wall-thickness is less than 4%.This method provides a new approach for near-net shape forming of nickel based super-alloy thin-walled parts with variable diameter sections.

Research on Influence of Cutting Conditions on Roundness of Ultra-thin Wall Parts in Ultrasonic Vibration Cutting

In the paper, the experimental researches were carr ie d out to discuss the roundness forming rule and the influence of cutting paramet ers on roundness by ultrasonic vibration cutting of the camera’s guiding drawtu be with 47.75 mm diameter and 0.6～1.5 mm wall thickness. The research results s h ow that the roundness error of ultra-thin wall parts in ultrasonic vibration cu tting is only one third of that in common cutting. The relations between the rou ndness error and the cutting parameters behave as: (1) The roundness error in co mmon cutting decreases gradually with the rise of cutting speed, while in ultras onic cutting, the roundness changes not obviously till the cutting speed is up t o a value, which is nearly equal to one third of the critical velocity. Then the roundness of workpiece will begin to increase slowly. (2) The roundness error i ncreases along with the feed rate both in common cutting and ultrasonic cutting. (3) Within the range of cutting depth in experiment, the influence of cutting d epth on the roundness error is more obvious in common cutting than that in ultra sonic vibration cutting. The conclusions are useful in machining such precise ul tra-thin wall parts. According to the tests, the following conclusions can be o btained: 1) Compared with common cutting, ultrasonic cutting can decrease effect ively roundness error of the workpiece. Under the same condition, the roundness error of the ultra-thin wall part in ultrasonic turning is about one third of t hat in common cutting. 2) In common cutting, cutting depth and feed rate have mu ch influence on the roundness and the influence of cutting velocity is little. W hile in ultrasonic cutting, the roundness was influenced heavily only when feed rate is more than 0.1 mm/r and cutting speed is more than 1/3 of the critical ro tation speed, cutting depth has little influence on the roundness in the experim ent. 3) Kerosene-oil is an optimum cutting fluid in machining ultra-thin wall workpiece. 4) To machine the ultra-thin wall precision part, ultrasonic cutting is the perfect method which can decrease the roundness error effectively an d ensure high quality of the surface.

Optimization of material removal strategy in milling of thin-walled parts

The optimal material removal strategy can improve a geometric accuracy and surface quality of thin-walled parts such as turbine blades and blisks in high-speed ball end milling.The dominant conception in the material removal represents the persistence of the workpiece cutting stiffness in operation to advance the machining accuracy and machining efficiency.On the basis of theoretical models of cutting stiffness and deformation,finite element method (FEM) is applied to calculate the virtual displacements of the thin-walled part under given virtual loads at the nodes of the discrete surface.With the reference of deformation distribution of the thin-walled part,the milling material removal strategy is optimized to make the best of bracing ability of still uncut material.This material removal method is summarized as the lower stiffness region removed firstly and the higher stiffness region removed next.Analytical and experimental results show the availability,which has been verified by the blade machining test in this work,for thin-walled parts to reduce cutting deformation and meliorate machining quality.

Research of precise pulse plasma arc powder welding technology of thin-walled inner hole parts

The inner hole parts played an oriented or supporting role in engineering machinery and equipment,which are prone to appear surface damages such as wear,strain and corrosion. The precise pulse plasma arc powder welding method is used for surface damage repairing of inner hole parts in this paper. The working principle and process of the technology are illustrated,and the microstructure and property of repairing layer by precise pulse plasma powder welding and CO2 gas shielded welding are tested and observed by microscope,micro hardness tester and X-ray residual stress tester etc. Results showed that the substrate deformation of thin-walled inner hole parts samples by precise pulse plasma powder welding is relatively small. The repair layer and substrate is metallurgical bonding,the transition zones( including fusion zone and heat affected zone) are relatively narrow and the welding quality is good. It showed that the thin-walled inner hole parts can be repaired by this technology and equipment.

Initial residual stress experiment and simulation of thin-walled parts for layer removal method

Thin-walled parts have low stiffness characteristic. Initial residual stress of thin-walled blanks is an important influence factor on machining stability. The present work is to verify the feasibility of an initial residual stress measurement of layer removal method. According to initial residual stress experiment for casting ZL205 A aluminum alloy tapered thin-walled blank by a common method,namely hole-drilling method,three finite element models with initial residual stress are established to simulate the layer removal method in ABAQUS and ANSYS software. By analyzing the results of simulation and experiments,the cutting residual stress inlayer removal process has a significant effect on measurement results. Reducing cutting residual stress is helpful to improve accuracy of layer removal method.

Effects of Carburized Parts on Residual Stresses of Thin-Rimmed Spur Gears with Symmetric Web Arrangements Due to Case-Carburizing

This paper presents a study on effects of carburized parts on residual stresses of thin-rimmed spur gears with symmetric web arrangements due to the case-carburizing. The carbon content of each element of the FEM gear model due to carburizing was obtained according to Vickers hardness Hv - carbon content C% and C% - d (distance from surface) charts. A heat conduction analysis and an elastic-plastic stress analysis during the case-carburizing process of thin-rimmed spur gears with symmetric web arrangements were carried out for various case-carburizing conditions by using the three-dimensional finite element method (3D-FEM) program developed by authors, and then residual stresses were obtained. The effects of the carburized part, the web structure, and the rim thickness on the residual stress were determined.

基于旋量理论的镜像加工运动学建模及轨迹自动修调研究

针对镜像加工过程中结构变形致使加工精度难以控制的问题,建立了基于旋量理论的镜像加工剩余壁厚运动学模型,综合考虑零件加工要求及镜像约束关系,提出了镜像加工“支撑-铣削”轨迹生成方法,建立了针对工件变形补偿的镜像支撑轨迹修调模型,实现了镜像加工“支撑-铣削”轨迹自动修调。栅格壁板镜像加工验证试验结果表明,提出的镜像加工“支撑-铣削”轨迹生成和自动修调方法可以满足镜像加工剩余壁厚要求。

框类薄壁件装夹布局与加工参数研究

针对航空隔框类薄壁件在铣削加工中极易产生变形等问题,通过有限元软件ABAQUS研究了铣削过程中装夹布局和铣削参数对薄壁件加工变形量的影响。首先根据装夹有限元模型,分析装夹位置和夹紧顺序对薄壁件变形量的影响,并在装夹仿真的基础上建立了铣削加工模型,设计正交试验得到不同铣削加工参数下薄壁件的变形量;其次以仿真数据为样本,使用BP神经网络和遗传算法对装夹布局和铣削参数进行优化;最后对优化结果进行实验验证,结果显示仿真与实验数据比较符合,最小偏差为4.38%,最大偏差为9.35%。研究结果表明:通过有限元仿真试验辅助选取薄壁件的铣削加工参数,能充分地提高航空薄壁件的加工质量。

基于双混联机器人协同运动控制的薄壁件镜像铣削研究

为提高薄壁件镜像铣削过程中的加工质量,本文提出一种针对双混联机器人镜像铣削的协同运动控制策略。首先,结合机器人运动控制特点,研发出一种双CPU主从控制架构的开放式数控系统,以实现人机交互和运动控制;然后,为实现双机协同运动并提高薄壁件加工质量,在数控系统中集成了4大关键技术,分别是双机器人的镜像路径生成、同步速度规划、协同运动学和运动误差实时补偿;最后,基于自主开发的集成式镜像铣削数控系统,开展了单点和多点支撑、双机协同与非协同加工的平面薄壁件槽铣削试验,多点支撑的平面铣削试验,大曲率路径高速协同运动试验与曲面薄壁件槽铣削加工试验。试验结果表明,提出的协同运动控制策略能够保证双机器人具有较高的同步位置精度。此外,多点支撑方式在保证薄壁件铣削壁厚的同时,还可提高工件铣削的颤振稳定性。

薄壁结构件的正向吸附辅助支撑钻削工艺研究

航空航天领域中薄壁结构件的连接装配要求加工高精度的连接孔,但此类结构件钻削加工时变形大、易振动,严重影响制孔精度和表面质量,传统装夹方法存在装夹跨距大、难以充分有效支撑等问题。本文提出通过正向吸附辅助支撑,提高薄壁结构件加工时的局部刚度,进而提高薄壁结构件的加工质量,并通过仿真和试验相结合的方式研究了正向吸附辅助支撑对薄壁结构件钻削加工的影响。结果表明,在本文仿真和试验条件下,正向吸附辅助支撑可使钻削位置刚度提升40倍以上,孔壁粗糙度值降低67%以上,圆度公差降低60%以上,孔径偏差降低50%以上,同一孔的靠近出口、入口位置的孔径偏差降低90%以上。可见,正向吸附辅助支撑可显著提高薄壁结构件的制孔精度和质量。

小熔池激光沉积制造薄壁件沉积宽度的模型预测及试验研究

将激光沉积制造的热物理过程与薄壁件的几何特性相结合,基于层间沉积过程中的能量守恒关系建立了可以适配于小熔池激光沉积制造薄壁件沉积宽度的预测模型。该模型详细阐述了沉积宽度与激光功率、扫描速度与送粉速率之间的关系。利用Ti–6Al–4V(TC4)粉末沉积制备了多组样品来进行预测模型的验证,结果表明,该模型可以准确地预测不同工艺参数下薄壁件的沉积宽度,提高了试验参数匹配的准确性与效率,并为小熔池激光沉积制造工艺成形精度控制奠定了理论基础。

基于PC/ABS薄壁成型的雾化器机筒注射模设计

针对雾化机机筒薄壁塑件模腔流长比为77.8,并且采用PC/ABS进行注塑要求的特点,设计了1副两板2次开模的自动化注塑成型。模具中,针对塑件模腔的浇注,设置了2个潜伏式浇口,保证模腔的充填效果。为实现塑件的自动脱模,设计了3个脱模步骤,相应的机构及机构动作为采用了2副哈夫滑块机构用于塑件外壁的脱模,2副哈夫滑块机构均依靠模具打开的开模动力分次实施抽芯;第一副哈夫滑块机构用于定模一侧外壁的侧抽芯脱模,其通过动模侧的第一次开模打开驱动,完成先抽芯动作;第二副哈夫滑块机构用于动模一侧外壁圆环型凹槽的侧抽芯脱模,其通过动模侧的第二次开模打开驱动,完成抽芯动作。为实现模具2次开模按顺序进行,该模具中设计了一种开模控制机构,机构通过解锁插杆驱动移动锁芯实现与锁钩的锁闭/开锁功能,从而实现了模具开/闭模动作的有序进行。

激光沉积制造零件表面粗糙度预测及控制方法研究

针对激光沉积制造(LDM)成形零件表面粗糙度高、成形质量差,以及打印后必须进行机加工等后处理的问题,自主搭建成形平台,使用“小光斑、小层厚、小粉末粒径”的工艺方法打印具有不同倾斜角度的薄壁零件,并考虑熔道搭接、层间抬升量及成形角度的影响,基于增材制造分层切片原理,给出了不同几何特征下典型薄壁零件的理论表面粗糙度预测模型,通过实际打印薄壁零件对其进行三维共聚焦观测表面形貌和粗糙度,测量验证了所提出的表面粗糙度预测模型的正确性,并在此基础上提出了激光沉积制造零件表面粗糙度的控制策略。

基于LSO-BP模型的铝合金薄壁零件铣削力预测

铣削力是铝合金薄壁零件铣削加工中很重要的过程参量,其信息的准确反馈对减小工件变形有着十分重要的作用,因而需要实现铣削力的精准预测.首先,通过铝合金薄壁零件铣削加工的仿真实验获得铣削力数据;其次,针对传统BP神经网络的弊端利用狮群算法进行改进,并将铣削力数据导入改进后网络进行训练,从而建立LSO-BP预测模型;最后,分别利用LSO-BP模型、PSO-BP模型和传统BP神经网络模型预测铣削力.均方根误差、平均相对误差和相关系数等评价指标的对比结果表明,LSO-BP模型预测铣削力的性能明显优于PSO-BP模型和传统BP神经网络模型.

航空薄壁零件切削加工技术研究进展

航空薄壁零件的加工精度和效率直接影响飞机的性能和可靠性。本文系统综述了航空薄壁零件切削加工技术,包括夹具技术、加工变形预测与控制方法、颤振预测与控制技术,以及数字孪生技术应用等多个方面。夹具技术详细研究了各种夹具的操作模式、结构特点、功能与应用等方面。变形预测与控制分析了薄壁件加工变形原因,并介绍了相关的控制技术和方法。颤振预测与控制探讨了切削过程稳定性分析技术和颤振控制技术,包括在线监测与识别、主动与被动控制技术和方法。数字孪生技术的应用部分介绍了该技术在薄壁件加工中的实际应用情况。通过对航空薄壁零件加工技术的系统综述,全面深入地介绍了相关内容,可为学者们的研究提供参考与指导。

基于直驱机床的航空整体叶轮加工效率优化方法研究

为解决航空叶轮在复杂五轴联动加工过程中的效率和精度控制难题,本文基于直驱机床围绕加工参数对表面粗糙度和加工时间的影响进行了深入分析。首先通过与传统机床进行加工对比,证明了直驱机床的精度与速度方面的优势;其次针对原点坐标的研究揭示了原点位置对加工效率的影响,尤其是当原点接近A、C轴中心时,加工效率显著提高;最后通过正交试验法研究了转速、每齿进给量、切宽这3个关键因素,并发现每齿进给量是影响表面粗糙度的主导因素,其次是切宽,而转速的影响较小。在保证粗糙度小于1.6μm的前提下,以转速20000 r/mim、每齿进给量0.03 mm、切宽0.6 mm的参数组合获得最优结果。基于优化的工艺参数不仅提升了加工效率,节约了43.3%的加工时间,还确保了加工质量,为航空叶轮的精密加工提供了重要的技术参考,同时为基于直驱机床的复杂零件高效加工提供实践指导和理论依据。

基于VERICUT的薄壁零件数控加工技术研究

薄壁零件结构复杂,精度要求高,加工效率低,其加工难度大,程序复杂,加工易出现碰撞、干涉和超程等问题,数控加工过程中没法人为的来判断数控程序的正确性。针对这一问题,从数控加工的装夹方式入手,研究薄壁零件的数控技术。在验证数控程序正确性的数控虚拟仿真加工软件VERICUT9.1中模拟加工零件,杜绝了加工过程中的碰撞、干扰、超程等问题,使试切时间减少,开发周期缩短,产品生产效率提高。最终,该机床的虚拟仿真加工模型以及数控程序的正确性和有效性,通过FANUC加工中心对该零件的实际加工得到有效验证。