提高电火花微小孔加工质量的研究进展

电火花微小孔加工是电火花加工领域的一个重要方向。因其加工设备简单、加工精度高且无切削应力等优点，成为众多难切削材料微小孔加工中的最常用加工方法。传统电火花微小孔加工中存在加工碎屑排出困难，间隙短路，频繁抬刀及二次放电等问题。针对这些问题，本文在微小孔加工技术理论基础上，系统阐述了电极形状和电极运动方式的改进，以及电火花微小孔加工与其他技术复合的加工方式，包括磁场辅助、超声振动辅助、电解电火花复合微小孔加工，其中与其他技术复合是进一步提升电火花微小孔加工性能的有效方式，将是未来研究的重点之一。归纳了目前技术改进及复合加工技术中存在的问题。最后对电火花微小孔加工的发展趋势进行了展望。     

电火花加工加速喷油咀的生产

美国Lucas工业公司在Greenville的CAV喷油设备子公司采用了两台高生产率的电火花加工机床加工柴油机喷油咀曲面上一个直径为0.039英寸(≈0.99毫米)的小孔(图1),同时加工192(每台96件)件,只需一个工人看管,每月可绰绰有余地完成140,000件的任务     

低速单向走丝电火花线切割钛合金TC4表面粗糙度试验研究与建模

低速单向走丝电火花线切割在钛合金加工领域有着不可替代的作用和地位,但微观放电的复杂性决定了其难以建立有效的表面粗糙度数学模型,同时现有机床系统中并没有针对钛合金材料的加工参数。以钛合金TC4为试验研究对象,采用Design-Expert设计Box-Behnken试验并通过三维轮廓仪和扫描电子显微镜对加工后的表面形貌、功率频谱和重熔层进行分析。观测结果表明：电火花加工表面没有明显纹理,为各向同性,不同于磨削加工表面;当峰值电流为40 A,开路电压为100 V,脉冲宽度为18 μs时,裂纹延伸至TC4基体。利用响应曲面法通过模型选择和显著性检验得出三维表面粗糙度的2阶数学模型,能正确地映射出低速单向电火花线切割钛合金的工艺规律。为了提高模型预测精度和泛化能力,引入BP神经网络建立组合模型,试验验证结果表明：样本内相对误差均值由4.33%降低到3.26%,样本外相对误差均值由13.31%降低到8.50%,为电火花加工工艺仿真提供新的方法和途径。     

TC4钛合金电火花高效铣削加工效率研究

钛合金材料以其优异的机械性能在航空航天工业中得到了广泛的应用,目前钛合金切削性能差的问题一直没有得到妥善解决,制约了钛合金工业应用范围的推广。以TC4钛合金加工效率为研究对象,通过使用长脉宽大电流脉冲电源,采用电火花铣削加工的方法实现了钛合金的高效加工。利用设计的正交实验对电火花铣削加工钛合金过程中主要加工参数,分别为脉宽、脉间、峰值电流、电极转速、冲液压力和切削深度等对加工效果的影响进行了实验研究。通过加工参数优选、极差分析及显著性分析等方法对加工参数对加工效率的影响进行了分析,使用加工效率预测公式对加工所能达到的最大加工效率进行了预测。最终在正交实验分析的基础上,通过进一步进行实验,采用脉宽为2 000 μs、脉间为100 μs、峰值电流为635 A、电极转速为800 r/min、冲液压力为1.5 MPa和切削深度为3 mm时,使得电火花铣削加工钛合金的加工效率最高可以达到9 000 mm³/min, 并使用电子扫描电镜对钛合金被加工表面的受热影响层进行了检测分析,验证了使用电火花铣削对钛合金进行高效加工的可行性。与传统切削方法相比,电火花铣削加工的加工精度有限,表面质量较差,但是由于采用石墨材料作为电极,相同体积钛合金的去除其电极损耗的成本只有刀具加工的10%左右,因此非常适合应用于航天航空工业制造中大量存在的需要大体积材料去除的钛合金等难加工材料的粗加工。     

深小孔脉冲电解加工精度控制研究

为了实现电解加工深小孔的精度控制,建立线性去除率动态数学模型,分析影响动态方程的工艺参数,通过在镍基合金上进行电解加工深小孔试验,分析了脉冲宽度、工具电极进给速度、工具电极绝缘层有无裸露对深小孔加工精度的影响。结果表明：采用较大的脉冲宽度、较大的工具电极进给速度、绝缘层覆盖全部工具电极,有利于提高孔的加工精度。     

钛合金薄壁件超声椭圆振动铣削研究

针对航空领域中钛合金薄壁件在铣削过程中存在切削力大、加工精度低等问题,提出了超声椭圆振动铣削方法进行钛合金薄壁件的加工。超声椭圆振动铣削时,刀尖的特殊运动轨迹使刀尖具有高线速度特性和高频断续切削特性,平均切削力大为降低,从而增强了铣刀的切削能力,提高了切削加工精度。利用自制的超声铣削刀柄系统,对钛合金试件进行铣削实验,结果表明与普通铣削相比,超声椭圆振动铣削的切削力可降低达50%,零件的形位精度得到了显著提高。     

深孔的直线度在线检测研究

介绍了一种新的深孔直线度在线检测方法－逐次两点误差分离法，并研制一种深孔直线度在线检测系统，该系统的特点是可在孔加工机床上在线检测，并能分离出机床的导轨直线度误差。     

重心驱动在数控深孔螺旋拉床整机设计中的应用

重心驱动是一项可以缩短加工时间、提高加工面质量的技术。在数控深孔螺旋拉床整机设计中,采用了重心驱动原理,结果表明,该设计能在结构上减少机床振动,提高机床性能。     

超声振动切削加工技术的研究进展

综述近年来我国超声振动加工技术在超声振动装置、加工刀具和切削机理方面的一些研究成果,以及超声振动切削加工技术在难加工材料加工、深孔钻削、超声复合加工等方面的应用研究进展,并探讨了超声振动技术未来的发展方向与研究重点。     

深孔数控变径超声椭圆振动镗削加工方法研究

深孔镗削采用超声椭圆振动技术具有大幅降低切削力、抑制颤振和提高工件加工精度的优势。为充分发挥超声椭圆振动切削和数控加工优势,在研究固-固界面传振理论基础上,针对长径比大于20 的复杂内腔深孔件的加工难题,提出了一种新型数控变径超声椭圆双刃镗削加工方法,通过切削对比实验验证了超声变径双刃数控镗削比普通镗削更具有提高加工精度、表面质量、抑制颤振的优势。与普通切削相比,在相同加工参数下,加工孔直径16 mm,长径比23颐1,单边落差0. 5 mm 的深孔内腔轴类零件,超声镗削可达到表面粗糙度Ra 为0. 65 μm,表面质量和加工精度满足设计要求。数控变径超声椭圆振动镗削加工方法为深孔复杂内腔加工提供了一条有效途径。     

Expert Systems Aimed at General Design of Projectiles

Expert systems aimed at the general design of projectiles can implement a series of intelligent designs, such as the design of HE shell, the scheme expounded and proved, the emulation analysis and calculation, etc. Aiming at the product design feature, the expert system adopts the object-oriented knowledge representation and all kinds of inference control engines to describe and reason the relevant knowledge regarding the product through the microcomputer. It embodies the foundation of emulation analysis and simulated manufacturing of the shell. It makes use of the method that knowledge expression is combined with condition of inference to carry out the overall design and emulation and reference.The paper gives the ways through which the functions can be achieved, gives the modularization of reference and the design methods of systematization, puts forward the method of knowledge expression and working interface, and supplies a platform for similar products of the shell category that can be quickly designed.     

Three-dimensional Numerical Simulation of Combustion Field in the Combustion Chamber

In order to study the effect of rotation on the combustion in the underwater vehicle, a two-phase turbulent combustion process is described with Reynolds stress turbulence model, eddy-dissipation turbulent combustion model, P-1 radiation model and particle tracking model of liquid. The flow in the rotating combustion chamber is simulated at two different working speeds, 0 r/min and 1 000 r/min by Fluent software. The temperature, gas velocity, static pressure of wall and fuel concentration are computed and compared. The results show that the combustion in rotating combustor is faster and more effective.     

Software Communication Architecture Implementation and Its Waveform Application

This paper attempts to do a research on the development of software defined radio（SDR） based on software communication architecture（SCA）. Firstly, SCA is studied and a whole reference model of SCA3.0 core framework （CF） is realized; Secondly, an application-specific FM3TR waveform is implemented on the platform of common software based on the reference model; Thirdly, from the point of view of real-time performance and software reuse, tests and validations are made on the above realized CF reference model and FM3TR waveform. As a result, the SCA-compliant SDR has favorable interoperability and software portability and can satisfy the real-time performance requirements which are not too rigorous.     

Parameter Identification for the Valve Control Cylinder System of a Hydraulic Manipulator

In mechanical, hydraulic and electronic systems, the determination of system parameters is often challenging because liquid parameters often change significantly, due to variations in working and environmental conditions. Therefore, it is of significant practical importance to identify those parameters through experimental procedures. A systematic approach to identifying parameters in the valve controlling cylinder system of hydraulic manipulators is provided. It first derives the transfer function of the system, and then uses P control of PID control to predict system parameters. The predicted parameters are further validated using PID control. The prediction through simulation using MatLab language is utilized, which agrees well with experimental results.     

Dynamic Simulation of the Tank Gun Recoil Response

By using the ATV module of MSC. ADAMS, the dynamic simulation of recoil response of tank gun is analyzed.How the recoil force affects the bodywork and the suspension during gun firing, as well as the changing status of the gun muzzle‘s velocity are gained. All results and analyzing methods are offered for the designing basis of optimizing tank vehicle-gun match. The constructive exploration is beneficial to improving the general capability of tank.     

Survey of Controllable Suspension System for Off-road Vehicles

The controllable suspension system can improve the performances of off-road vehicles both on road and cross-country. So far, four controllable suspensions, that is, body height control, active, semi-active and slow-active suspensions, have been developed. For off-road vehicles, the slow-active suspension and the semi-active suspension which have controllable stiffness, damping and body height are more appropriate to use. For many years, some control methodologies for controllable suspension systems have been developed along with the development of modern control theory, and two or more original control methods are integrated as a new control method. Today, for military or civilian off-road vehicles, the R&D of controllable suspension systems is ongoing.     

Nitrosation and Nitration of Tetraacetyldibenzylhexaazaisowurtzitane

Tetraacetyldibenzylhitane (TADBIW) was subjected to debenzylation by nitrosating with inorganic materials available commercially to synthesize tetraacetyldinitrosohexaazaisowurtzitane (TADNSIW). TADNSIW was purified, and its structure was determined by FTIR, 1H NMR, MS and element analysis. The debenzylation reaction of TADBIW gave quantitative benzaldehyde as a by-product. This indicates that the reaction produces an imine cation as an intermediate. Hexanitrohexaazaisowurtzitane (HNIW) was prepared from unpurified TADNSIW with the yield over 96.0 % and the purity more than 98.0 %. And the mechanism of the reaction from TADNSIW to HNIW is proposed to be oxidation of nitroso and nitration of acetyl on the molecule of TADNSIW, This reaction system involved is simple, and the reaction can complete within a short time and under mild conditions. The product can be easily to separate and the waste disposed readily.     

An Efficient Key Agreement Framework to MANET

Protocols for key management are compared and evaluated from the point of view on mobile ad hoe networks （MANET）. The issues of fault-tolerance and efficiency of key distribution protocols for group communications in MANET are addressed. Most key distribution protocols existing today are primarily designed for wlre-line networks. These protocols either fail to work as intended or cannot work at all when they are applied to the demanding environment of MANET. Parameters and performance of different protocols are analyzed, and then a fiat is given out, on which new protocols or existing ones are designed and modified, so that they can be robust, scalable and efficient in MANET.     

Finite Element Analysis of Fretting Behavior Between an Engine Cylinder Block and a Main Bearing Cap

The finite element analysis of the fretting behavior between a cylinder block and a main bearing cap is presented. The stresses, relative fretting slip, fretting friction work parameter W and crack initiation location parameter G on the fretting contact surface of the cylinder block are obtained and analyzed. It shows that the fretting fatigue problem of the cylinder block can be quantitatively explained by W or G. The effects of pretightening force, friction factor and material combination of the cylinder block and the main bearing cap are studied. The computational results indicate that the fretting fatigue of the cylinder block can be allayed by increasing the elastic modulus of the cylinder block, but not by changing the other two factors.     

A Physical Model of Electromagnetic Force from PEMA Acted on Metal Projectiles

Electromagnetic armor is a new conceptual combat vehicle technology, which improves remarkably the defensive capability and maneuverability of vehicles. The authors present definitely to apply the electromagnetic theory to analyze the electromagnetic armor. Based on electromagnetics, the experienced expression of projectile and the physical model of PEMA （passive electromagnetic armor） are obtained when electric current flows through the system, and a computer sim- ulation is given.