铝合金薄壁盒体高速加工工艺研究

通过对铝合金薄壁盒体在高速加工机床和刀具系统及高速编程软件PowerMILL环境下加工过程的研究,详细论述了铝合金薄壁类零件的加工工艺、高速加工编程策略、加工参数,并提出了较为完整、可行的加工思路。     

基于UG NX的汽车铝合金轮毂制造工艺研究

根据汽车铝合金轮榖的加工工艺要求,运用UG NX进行加工工艺设计、使用专用工装夹具,设置加工方法和走刀路线,并完成铝合金轮榖的实际加工。结果表明:经过使用专用夹具与数控加工工艺优化,汽车铝合金轮毂加工精度和表面质量有明显提高,提升了经济效益和稳定的质量保证。     

基于Powermill的模具高速加工编程及应用研究

从高速加工的工艺要求出发,阐述了采用Powermill进行模具高速加工编程的策略,合适的高速加工方法的选择、走刀方式的控制等,并以衣架模具为加工对象,制定合理的加工工艺和切削参数,完成高速加工编程。     

连续加工中线切割工作液对加工的影响

测试了高速走丝线切割机工作液在连续加工中电导率的变化情况，分析了电导率对工艺指标的影响，尤其是对加工速度的影响。     

高速走丝线切割加工工艺效果仿真系统

建立了高速走丝线切割加工工艺效果仿真系统,可预测加工工艺效果,具有较高的预测精度,并能实现加工参数的优化选取。通过训练模型的功能,该仿真系统能适用于各种类型的高速走丝线切割机,有助于进一步提高高速走丝线切割机的自动化程度和开发智能化系统。     

消除线切割加工塌角现象简法

《电加工》1991年第4期上“高速走丝电火花线切割拐角加工”一文，阐明了高速走丝电火花线切割加工中塌角产生的原因，总结出克服塌角现象的几种切割工艺方法，其中一种是切割路径安排法。在长期的数控电火花线切割编程工作中，我对精度要求较高的零件在凸拐角处的切割工艺方法是：顺着拐角初始边的切割方向，越过拐角多切割出0．3m的长度，然后再顺着原路返回拐角处，接着按原程序切割，如图1。     

高速走丝线切割加工中不稳定加工状态分析

从高速走丝电火花线切割加工的工艺特点出发,分析了一些非加工参数带来的断丝故障和不稳定加工状态,提出了相应的预防措施和解决方法,能切实有效地提高切割加工的稳定性,减少断丝几率.     

往复走丝电火花线切割机床工艺特点及现状

介绍了往复(高速)走丝电火花线切割机床加工工艺指标的研究进展,对其高效稳定切割、高厚度切割、大锥度切割、稳定多次切割的实现,以及半导体和其他特种材料切割等工艺目前所能达到的工艺指标、存在的问题、解决思路等,结合往复走丝的加工机理进行了分析.研究认为往复走丝电火花线切割加工有其自身独特的工艺特点,并将获得持续的发展.     

高速走丝线切割机多次切割放电波形的检测和分析

高速走丝线切割机在低速走丝条件下多次切割加工是一种新的工艺方法。本文检测利用此新方法加工时的电压、电流波形 ,并对其作简要分析 ,以此为据提出了改进多次切割加工系统的几点建议     

模具高速加工中的走刀路径策略

刀具轨迹生成方法是模具高速加工数控编程的基础和关键。从优化高速加工工艺策略的角度．详细阐述高速加工中常见的进退刀方式、走刀方式、移刀方式、拐角加工和清根加工等策略。并对常用CAM软件中73具轨迹策略进行总结和分析。     

人造金刚石新型槽刀的研制

本文针对硬质合金刀具切削中硅铝合金活塞槽存在的问题,研制出一种新型人造金刚石切槽刀。使用该刀,加工效率可提高二倍,加工成本降低62％,并且还提高了加工精度。从本文研究结果可以看出,人造金刚石刀具加工硅铝合金与硬质合金刀具相比,具有许多优点,是值得进一步开发和推广的刀具。本文不仅探讨了人造金刚石切槽刀的制造,还探讨了对刀具备参数的检测。     

Solid-state recycling of aluminium alloy swarf through cold profile extrusion and cold rolling

In this study, the possibility of solid-state recycling of aluminium alloy machining swarf using cold extrusion and a subsequent cold rolling process is investigated. Cast Al-Si alloy swarf was cold compacted into billets and successfully profile-extruded into square bars with a rectangular cross-sectional aspect ratio of 1:1.8 under an extrusion ratio of 4 or more. After annealing, the extruded bars underwent multi-pass cold rolling into 1-mm thick strips with a total rolling reduction of 85%. Optical microscopy demonstrated that in material recycled using only an extrusion process, coarse residual voids existed in regions where insufficient plastic strain was introduced, causing a visible expansion of the material during heat treatment. However, uniaxial tensile tests showed that extrusion-recycled material had a higher mechanical strength than the original aluminium alloy, implying sufficient bonding among the individual pieces of machining swarf. It was also found that the strength and density of material recycled through extrusion and an additional rolling process were superior to material recycled using extrusion only. Moreover, it was observed that the ductility of the recycled materials was inferior to that of the original aluminium alloy.     

A new method of automatic polishing on curved aluminium alloy surfaces at constant pressure

This paper presents original research results of automatic polishing on curved surfaces of aluminium alloy moulds at constant pressure. The automatic polishing of aluminium alloy material is achieved. A parameter S is defined, which can express the comprehensive influential factors in the automatic polishing process and give a relationship among the polishing quality and the various machining variables. Based on this, a new method for comprehensive control of polishing quality is suggested.     

7A04铝合金复杂零件超塑性成形研究

在对空心圆锥体外侧表面带凸耳的7A04铝合金零件超塑性成形结构工艺性分析的基础上，进行模具设计和超塑性成形试验。结果表明：该零件在超塑性成形过程中，金属将同时向凸耳和空心圆锥体模腔内流动充型，导致变形阻力增大而无法成形；必须分两步进行超塑成形：先成形空心圆锥体，再成形凸耳。与原机加工工艺相比，超塑性成形该零件的工艺简单，节省材料60％以上。     

Filiform corrosion behaviour on machined AA7150 aluminium alloy

The microstructure and the filiform corrosion behaviour of machined AA7150 aluminium alloy were investigated using scanning and transmission electron microscopies combined with potentiodynamic polarization and filiform corrosion testing, respectively. It is found that the grain refinement, redistribution of alloying elements, and elements segregation at grain boundaries are evident within the near-surface region on the machined AA7150 aluminium alloy. The corrosion susceptibility of machining introduced near-surface deformed layer is significantly improved caused by the modified microstructure associated with severe deformation. Filiform corrosion resistance on the machined surface is obviously decreased, due to the surface roughness associated with machining tracks and the presence of the electrochemically more active near-surface deformed layer introduced by machining.     

High-spend machining of aluminium using diamond endmills

Milling experiments on aluminum alloy were carried out using a laboratory-designed diamond endmill. The machining of aluminium alloy using a conventional tool at a conventional cutting speed generally results in short tool-life, poor surface quality and poor edge finishes because of the formation of built-up edges and burrs. The machining technology of aluminum alloy surfaces with a good surface finish and edge finishing is very important and required in many industries. The experimental results reveal the possibility of machining a mirror-like aluminum alloy without built-up edges and burrs using the designed diamond endmill at high speed.     

Recycling of aluminium alloy turning scrap via cold pressing and melting with salt flux

Among the various steps of aluminium production from liquid metal, a lot of scrap is generated due to machining operations. Therefore, recycling of aluminium scrap is an interesting subject because of the broad applications of this metal and low efficiency of processes used to recycle metal scrap. In this paper, the recyclability of aluminium alloy AA 336 turnings with different cold compacting pressures and a protective salt flux (NaCl–KCl–KF) has been experimentally studied. Various categories of compacted samples were melted at 750 °C in molten aluminium alloy AA 336 and also in the protective salt flux to recover aluminium alloy. In order to understand the amount of recycling of different samples, weight loss measurement was applied. From recyclability stand point it is shown that using protective salt flux is the best route, from the point of view of recyclability. Mechanical properties and chemical analysis of samples were approximately the same as the primary material produced by conventional casting process.     

7075铝合金预拉伸板消除残余应力的试验研究

铝合金预拉伸厚板是现代航空工业的重要结构材料，但厚板淬火残余应力的存在不仅使其在机加工过程中易出现翘曲变形，而且也明显降低材料的动态使用性能加KIC、KQC、抗腐蚀和疲劳性能。对7075铝合金厚板淬火时残余应力的分布进行了试验研究，结果表明：通过控制淬火介质的温度，能有效降低淬火后厚板中的残余应力。此外，通过分析淬火过程中残余应力的产生机理，提出了两种降低淬火过程中残余应力的新方法。     

Progress in fluidized bed assisted abrasive jet machining (FB-AJM): Internal polishing of aluminium tubes

This paper deals with the internal finishing of tubular components made from a high strength aluminium alloy (AA 6082 T6) using a fluidized bed assisted abrasive jet machining (FB-AJM) system.Firstly, a Taguchi's experimental plan was used to investigate the influence of abrasive jet speed, machining cycle, and abrasive mesh size on surface roughness and material removal trends. Secondly, the leading finishing mechanisms were studied using combined 3d profilometer-SEM analysis to monitor the evolution of the surface morphology of machined workpieces. Finally, the circumferential uniformity and precision machining of the inner surface of workpieces were tested by evaluating the values of the more significant roughness parameters in different circumferential locations.Consistent trends of surface roughness vs. operational parameters were measured, and significant material removal was found to affect the workpieces during machining. As a result, FB-AJM was found to preferentially machine the asperities and irregularities of the surface, thereby altering the overall surface morphology producing more regular and smoother finishing. Moreover, the good circumferential uniformity and machining accuracy FB-AJM guarantees even on ductile aluminium alloy workpieces ensure that this technology can be applied to a diverse set of industrial components.     

Cimatron软件在发泡模具制造中的应用

以头枕型芯的数控加工为例,结合自己多年的铝合金工件加工经验,介绍了头枕型芯的工艺规划和Cimatron编程,希望对数控加工工艺编程人员有一定的帮助和借鉴作用。