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 ras...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.展开更多
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 proce...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.展开更多
文摘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.
基金Sponsored by the National Natural Science Foundation of China(Grant No.,51475106)NSAF(Grant No.U1230110)
文摘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.
