切削技术在机械加工中的应用

机械加工是对结构复杂的零件进行再加工,加工工艺复杂,设计到模具、光学元件、集成电路、计算机技术等多个领域。金属切削加工是机械加工必不可少的手段,在机械加工过程中选择合理的切削刀具及切削用量是提高机械加工工件质量的保障,研究数控切削加工技术特点,对于提高加工工件精度具有重要的现实意义。     

切削数据库的最新研究进展

<正>1引言自1964年美国开发第一个切削数据库CUTDA-TA以来,经过近半个世纪的发展,切削数据库的理念已全面拓展。将计算机应用技术的最新成果与之结合,全面渗透到工程应用的各个领域。本文阐述最新计算机技术成果应用到切削数据库开发的最新进展情况。     

微机金属切削数据库的研究

简述了在微机上开发的金属切削数据库软件。使用该数据库中经过优化的切削用量及刀具几何参数,可降低机械加工消耗,提高经济效益,同时可为ＣＡＤ、ＣＡＭ、ＦＭＳ、ＣＡＰＰ、ＣＩＭＳ等提供基础数据。     

面向创新方法的切削工艺知识库研究

传统切削数据库通过数据查询,实例推理和规则推理来生成工艺方案,而面对大量的非典型切削工艺问题却无能为力。为了扩展切削数据库的应用范围,辅助工艺人员解决非典型切削工艺问题,基于混合推理和工艺创新设计方法,提出一种面向创新的切削工艺知识库模型。该知识库的关键技术在于:基于切削工艺实例的标准化表示构建实例库;基于切削工艺标准建立推理规则;基于工艺问题分类建立创新方法的策略。最后,基于上述模型,构建了切削知识库的结构、框架和原型系统。     

基于大数据模糊 PID 控制的切削机械加工稳定性分析

针对切削机械加工稳定性分析未考虑切削力信号和切削机械磨损之间的关系,导致切削机械加工稳定性较差的问题,提出一种基于大数据模糊 PID 控制的切削机械加工稳定性分析方法,对加工过程建模,同时通过历史切削机械加工数据组建切削力信号和磨损之间的映射关系。分析切削机械的加工性能,在构建数学模型的基础上,设计一种大数据模糊 PID 控制方法对切削机械加工稳定性实时控制,通过模糊控制规格对控制器参数实时调整,最终有效控制切削机械加工稳定性。仿真实验结果表明,在切削机械加工过程中,该方法可以有效控制切削机械加工稳定性。     

切削数据库的研究现状与发展

根据加工工件来优化选择刀具，包括刀具材料、刀具几何参数、刀具结构、切削参数和机床等切削数据，将关系到生产效率、生产成本及加工质量。建立切削数据库，向机械制造业提供合理或优化的切削用量，是增强企业竞争力最有效的措施之一。本文结合国内外切削数据库研究开发现状，探讨建立切削数据库的核心技术，分析切削数据库研究及应用过程中存在的问题，着重探讨切削数据库的发展趋势，指出切削数据库未来的研究方向将是集成化、智能化、实用化、网络化和标准化。     

欢迎订阅《工具技术》、《工具展望》

<正>《工具技术》创刊于1964年,是成都工具研究所主办的切削与测量工程综合性技术刊物,中文核心期刊,中国科技核心期刊。主要报道机械加工中切削与测量技术的最新进展,金属理论研究,刀具设计及应用,刀具磨削设备及工艺,刀具涂层及技术,刀具磨损和破损在线技术,新材料及难加工材料的切削技术,专用刀具的研发;新的测量方法研究与新型量具量仪开发,精密测     

基于动力学仿真优化的切削数据库研究

本文基于动力学仿真优化技术,开发了存储优化型仿真切削数据的数据库应用系统。选择SQL Server2000作为数据库管理系统,以C#与ADO.NET为开发工具,在ASP.NET平台下开发了B/S模式的基于动力学仿真的优化型切削数据库应用系统。     

复合材料切削刀具数据库的设计与实现

复合材料切削加工数据库是实现复合材料高效、精密及智能加工重要支撑,本研究开发了一款基于B/S结构的复合材料切削刀具数据库系统,包括刀具和加工工艺的信息查询、混合推理和信息管理等功能。对复合材料切削刀具数据库进行信息与功能需求分析,完成了数据库系统的总体框架设计和功能模块开发,阐述了混合推理技术在数据库系统中实现刀具和加工工艺参数推荐的过程,为用户构建了一个高效、实用的复合材料切削刀具数据库系统。     

微细铣削工艺数据库系统设计与开发

针对微细铣削技术对构建切削数据库,累积基础工艺数据的迫切需求,设计开发了基于C/S模式的微细铣削工艺数据库系统。首先对微细铣削工艺系统进行建模并依此模型进行数据库的结构设计以及系统的总体功能设计,然后详细介绍了系统中混合推理以及切削参数优化的具体实现。数据库可为微细铣削技术提供较好的数据支持。     

THE UNIFIED-GENERALIZED MECHANICS OF CUTTING APPROACH—A STEP TOWARDS A HOUSE OF PREDICTIVE PERFORMANCE MODELS FOR MACHINING OPERATIONS

This paper presents the series of on-going investigations, which led to the development of the 'Unified-Generalized Mechanics of Cutting Approach' to predictive modelling of various technological performance measures for the wide spectrum of machining operations used in practice. It is shown that this approach involved the development of generalized mechanics of cutting analyses of the cutting processes for machining with single edge and multi-edge (form) tools and the establishment of a generic database of basic cutting quantities and edge force coefficients. This was followed by the development of a methodology for modelling each machining operation used in practice, based on the generalized cutting analyses and database. The models developed for turning, drilling and milling operations as well as machining with form tools and the novel rotary tool turning operations are briefly described together with recent research on predictive modelling of ball end-milling and machine tapping operations. It is shown that the models for the different machining operations could be 'unified' into a modular computer application structure, drawing on the generic cutting analyses and database. This 'unified' approach could represent a step towards the development of a 'House of Predictive Models' sought by the CIRP Working Group on modelling of machining operations. The considerable scope for further research is discussed in this paper.     

基于数控铣削动力学仿真切削数据库系统的设计

数据库技术应用于金属切削领域越来越受到国内外制造业的重视.文中针对当前国内数控加工过程中加工参数的选择、存储等问题,在加工过程动力学仿真技术的基础上,开发了一套面向数控铣削动力学仿真的数据库管理系统.该系统以Microsoft.net架构开发,以微软主推的新一代网络编程语言C#实现,数据库管理软件采用SQL Server2000.可以有效地为数控加工行业提供动力学仿真优化参数,提高加工效率,系统也提供了数据维护功能,方便用户对加工参数进行修整.     

基于实例推理的高速切削数据库系统

由于目前十分缺乏合理适用的高速切削数据 ,使建立高速切削数据库遇到了很大困难 ,也在一定程度上限制了高速切削技术的推广应用。利用基于实例推理技术 ,可为建立高速切削数据库提供一个可行且有效的方法 ,即将以前切削加工积累的切削数据和经验存储在数据库中 ,为新的工件加工问题提供参考解决方案。建立了简洁可行的用结构化数据表示的实例描述模型 ,分析了实例相似度的计算问题并介绍了实例检索的具体方法。     

THE UNIFIED-GENERALIZED MECHANICS OF CUTTING APPROACH—A STEP TOWARDS A HOUSE OF PREDICTIVE PERFORMANCE MODELS FOR MACHINING OPERATIONS

Abstract

This paper presents the series of on-going investigations, which led to the development of the ‘Unified-Generalized Mechanics of Cutting Approach’ to predictive modelling of various technological performance measures for the wide spectrum of machining operations used in practice. It is shown that this approach involved the development of generalized mechanics of cutting analyses of the cutting processes for machining with single edge and multi-edge (form) tools and the establishment of a generic database of basic cutting quantities and edge force coefficients. This was followed by the development of a methodology for modelling each machining operation used in practice, based on the generalized cutting analyses and database. The models developed for turning, drilling and milling operations as well as machining with form tools and the novel rotary tool turning operations are briefly described together with recent research on predictive modelling of ball end-milling and machine tapping operations. It is shown that the models for the different machining operations could be ‘unified’ into a modular computer application structure, drawing on the generic cutting analyses and database. This ‘unified’ approach could represent a step towards the development of a ‘House of Predictive Models’ sought by the CIRP Working Group on modelling of machining operations. The considerable scope for further research is discussed in this paper.     

An experimental investigation on micro machining of fine-grained graphite

Industrial applications of the micro milling process require sufficient experimental data from various micro tools. Research has been carried out on micro milling of various engineering materials in the past two decades. However, there is no report in the literature on micro milling of graphite. This paper presents an experimental investigation on micro machinability of micro milling of moulded fine-grained graphite. Full immersion slot milling was conducted using diamond-coated, TiAlN-coated and uncoated tungsten carbide micro end mills with a uniform tool diameter of 0.5 mm. The experiments were carried out on a standard industrial precision machining centre with a high-speed micro machining spindle. Design of experiments (DoE) techniques were applied to design and analysis of the machining process. Surface roughness, surface topography and burrs formation under varying machining conditions were characterized using white light interferometry, SEM and a precision surface profiler. Influence of variation of cutting parameters including cutting speeds, feedrate and axial depth of cut on surface roughness and surface damage was analysed using ANOVA method. The experimental results show that feedrate has the most significant influence on surface roughness for all types of tools, and diamond tools are not sensitive to cutting speed and depth of cut. Surface damage and burrs analysis show that the primary material removal mode is still brittle fracture or partial ductile in the experimental cutting conditions. 3D intricate micro EDM electrodes were fabricated with good dimensional accuracy and surface finishes using optimized machining conditions to demonstrate that micro milling is an ideal process for graphite machining.     

微细深孔超声轴向振动钻削装置的设计

超声振动钻削属于脉冲式的断续切削。在深孔加工方面具有普通孔加工技术无法比拟的工艺效果。文章介绍了作者基于高频振动切削原理设计的一台超声轴向振动钻削装置的结构。并将该装置用于立式加工中心上对铝、铜等材料进行了切削加工实验。实验结果表明，超声振动加工可提高微细深孔的加工精度和表面质量。这种方法特别适合于软质材料的微细深孔的精密和超精密加工。     

水射流机床CAD系统中轨迹提取与图形反生成的实现

就水射流切割机床交互式图形系统中轨迹提取和轨迹反生成问题进行了研究。水射流切割机床CAD系统中由于图形的存储顺序与加工顺序不吻合,在生成数控代码之前必须将图形轨迹按顺序提取,然后将之存储到数据库中。为了验证数据库中轨迹数据的正确性,用VC 实现了轨迹的顺序提取和轨迹图形的反生成,以便与CAD系统中的图形进行比较。反复实验表明,该系统运行可靠,具有实用性,可以用于其他类型切割机床中。     

PCBN刀具多媒体数据库咨询管理系统

开发了PCBN刀具多媒体数据库咨询管理系统。该系统除具有一般数据库功能外 ,还具有PCBN刀具相关信息的多媒体技术咨询、数据管理、仿真及演示、网上查询等功能 ,可实现对PCBN刀具及加工信息的规范化管理与快速查询。     

基于Access的热切割机数控系统数据库设计

热切割机数控系统在加工过程中需要处理大量数据,为提高数据流操作的稳定性与高效性,提出了将Access数据库技术应用到数控系统数据存储中的一种方法。分析了热切割加工工艺参数及加工代码格式,设计了相应数据库字段,构建了热切割加工工艺参数表、加工程序表以及割缝补偿表,进而构建了热切割数控系统数据库,进行了数控系统数据库读写实验。实验结果表明,数据库读写性能稳定、效率高,满足热切割数控系统的加工要求。     

Smart Cutting Tools and Smart Machining: Development Approaches,and Their Implementation and Application Perspectives

Smart machining has tremendous potential and is becoming one of new generation high value precision manufacturing technologies in line with the advance of Industry 4.0 concepts. This paper presents some innovative design concepts and, in particular, the development of four types of smart cutting tools, including a force-based smart cutting tool, a temperature-based internally-cooled cutting tool, a fast tool servo (FTS) and smart collets for ultraprecision and micro manufacturing purposes. Implementation and application perspectives of these smart cutting tools are explored and discussed particularly for smart machining against a number of industrial application requirements. They are contamination-free machining, machining of tool-wear-prone Si-based infra-red devices and medical applications, high speed micro milling and micro drilling, etc. Furthermore, implementation techniques are presented focusing on: (a) plug-and-produce design principle and the associated smart control algorithms, (b) piezoelectric film and surface acoustic wave transducers to measure cutting forces in process, (c) critical cutting temperature control in real-time machining, (d) in-process calibration through machining trials, (e) FE-based design and analysis of smart cutting tools, and (f) application exemplars on adaptive smart machining.