光学玻璃的高效精密划切工艺研究

利用自主研发的FAD1210高精高效划片机,通过单因素试验法研究了装夹紧固方式、划片刀种类、切割水流量对K9光学玻璃划切性能的影响,且检测其崩边宽度及表面粗糙度来评价划切效果。结果表明:玻璃基板的紧固方式效果较好,UV膜次之,高温硅胶带较差;树脂结合剂划片刀划切玻璃的效果较理想,其崩边宽度较小、表面粗糙度较好,金属刀次之,电镀刀效果较差;切割水流量增大,玻璃崩边宽度和表面粗糙度逐渐减小,当切割水流量大于4.5 L/min时,划切效果趋于稳定。在玻璃基板紧固方式、树脂划片刀和切割水流量4.5 L/min的优化参数下划切K9光学玻璃,划切效果最佳,崩边宽度为5.8 μm,表面粗糙度R_a为10.5 nm。      

多功能激光切割焊接机的设计与研究

激光切割焊接机机械部分的设计是影响激光加工效率和质量的重要因素。本文设计了一种直线电机驱动的高速、高精度多功能激光切割焊接机,利用有限元分析软件ANSYS研究了多功能激光切割焊接机横梁的静、动态特性。其方法和结论对激光切割焊接机产品的研发有一定的指导意义和参考价值。     

划片刀配方对砷化镓晶圆切割崩裂的影响

利用试验设计方法(design of experiment, DOE),以不同配方的划片刀划切砷化镓晶圆,并检测其正、背、侧面的崩裂尺寸,找出划片刀配方对砷化镓晶圆切割崩裂尺寸的影响规律。研究表明:划片刀的磨料粒度与砷化镓晶圆切割质量密切相关,即磨料粒度越细,正、背、侧面崩裂尺寸越小;而磨料浓度和结合剂强度与砷化镓晶圆正、背、侧面的切割质量相关性并不显著。可通过缩小磨粒尺寸的方式提高划切质量,并视情况调整磨料浓度和结合剂强度。      

基于蚁群算法的激光切割工艺路径优化

切割工艺路径规划是影响钣金激光切割效率的关键问题之一,钣金件的激光切割工艺路径优化问题可以转化为带有约束条件的广义旅行商问题(GTSP)。为了保证钣金激光切割质量、提高切割效率,在进行切割路径规划时必须满足顺着切、不跨区域切割、走空程时尽量不经过已切割区域等工艺要求。建立了以上述工艺要求为约束、以空行程最短为目标的优化模型。在算法设计与实现上,首先通过建立零件信息的预处理机制进行工艺约束处理,然后运用蚁群算法进行模型求解,最后通过实际算例证明了该方法的有效性,即能够在满足工艺约束的前提下获得较优的切割路径。     

基于混合包络矩形的复杂轮廓激光切割路径规划

复杂轮廓的钣金激光切割路径规划是集成化激光切割系统中的关键问题之一,在依次优先满足嵌套图形先内后外的顺序切割、空走行程不经过已切割区域、尽可能不跨区域切割的工艺要求下,建立以路径规划时间和空走行程最短为目标的优化模型。在规划算法设计和实现上,首先对复杂轮廓进行预处理,计算每个轮廓的最小外接包络矩形;然后,利用遗传算法、复杂轮廓原边界角点与包络矩形边界角点的位置关系,进行激光切割路径的初步和精细规划;最后,通过该算法实现对钣金切割案例的精细路径规划,规划结果表明,该算法具有规划速度快、规划路径短和算法稳定性高的特点。     

全自动双轴精密划片机的研制

为提高划片机的划片质量和划片效率，研制全自动双轴精密划片机。整机采用了龙门式结构，工具轴Y1与Y2采用并列平行的结构设计，使用全闭环控制；旋转工作台采用DD马达直接驱动；上下料系统可实现多盘的全自动上下料。检测结果表明:Y1/Y2轴的全程定位精度达到 1.5 μm，Z1/Z2轴的重复定位精度达到 1.0 μm，工作台平面度达到 4.3 μm。划切试验结果表明:划切沟槽的实际深度与设计深度的最大误差为5.2 μm，划切痕迹的实际位置与设计位置的最大误差为4.8 μm，划切表面平整光滑，崩边小，无毛刺。与国内传统的单轴划片机相比，所研制的双轴划片机划片效率提高了80%，划片质量得到了明显提高。      

光伏组件全自动在线敷设机的设计

针对太阳能电池板(即光伏组件)在线敷设的生产特点和要求,对全自动在线敷设机的总体方案、传送系统和抓取系统进行结构设计,综合采用电机、气动和液压系统实现电池片串在线抓取、转向和搬运的功能,完成对光伏组件的排版与叠放。     

基于SolidWorks的激光去溢料机机构有限元分析

全自动激光去溢料机中的溢料去除机构使激光切割后的集成芯片溢料实现精准去除。针对采用Solidworks软件完成造型和装配设计的溢料去除机构,利用Simulation插件的有限元分析功能,对该机构分别进行应力、疲劳和屈曲有限元分析,研究其在载荷和材料等情况下导致的零部件损坏或变形,以此为依据提出合理的改进建议和措施,以保证零部件乃至机构设计的强度、刚度和稳定性。该方法也可用于自动化设备整机设计的合理性验证与结构改进和优化。     

电沉积超薄型金刚石外圆切割片的研制

随着大规模集成电路的发展,对硅片的要求越来越高。硅片切割为了提高精度和成品率,从七十年代中期开始,国外已由原来采用金刚石划片刀,激光划片刀发展到使用金刚石外圆切割片。这种外圆切割片在用计算机控制的专用切割机上使用。目前这是一种比较先进的硅片切割工艺。这种外圆切割片的规格为中φ50.8×0.025～0.050×40mm,即刀片的厚度为     

激光切割加工中CAPP系统的设计与研究

介绍了一种激光切割加工中CAPP系统工艺数据库设计与开发，该系统可以提供激光切割加工的各种加工方法和工艺参数的选择，实现激光切割工艺标准化，并为智能化工艺设计提供了基础。     

机床行业激光切割机控制系统的研发

为了满足国产激光切割机高速、高精度技术要求,研发出了一整套激光切割机控制系统。该系统将EtherCAT网络型高速运动控制和高精度机器视觉检测相结合,解决了传统金属切割设备采用普通PLC或单片机控制存在的接线复杂、运行速度慢、维修难度大和设计不灵活等问题。采用全自动机器视觉检测,替代了人工检测。调试结果表明:该系统不仅自动化程度高,可实现激光切割机高速、高精度运行,而且在产品品质也得到很大的提高,为国产激光切割机升级改造提供了强有力的技术支撑。     

基于二维激光切割机的型材多面切割装置方案设计

为满足在二维激光切割机上实现型材多面三维切割的需求,根据二维激光切割机结构、型材加工要求、机械加工夹具及自动控制等方面知识,对在二维激光切割机上加装型材夹紧、旋转装置提出三种设计方案并进行分析。与采用三维激光切割方案相比,大大节约投资。     

大型圆柱形铸件浇冒口切除与打磨一体化设备总体设计

针对当前大型圆柱形铝铸件浇冒口的清除主要采用手工清除、清除效率低、对工人身体危害大的情况,研发一种大型圆柱形铝铸件浇冒口自动切割和打磨机床。介绍机床的工艺方案和总体布局,对切割装置、打磨装置、废料夹持装置的机械结构进行介绍,重点阐述切割装置的设计。采用环形切割和打磨的方案,大大提高浇冒口的清除效率;更换定位元件,可以适用不同型号的圆柱形铸件,设备的适用性高,对其他类似产品的设计有一定的参考价值。     

FMS激光切割机柔性生产线

对FMS激光切割机柔性生产线进行整体介绍,系统分析构成整条生产线的各个组成部分。本生产线由国际先进的全自动立体仓库、高性能激光切割机等关键设备组成,包括三菱触摸屏、PMC轴同步运行控制、全自动上下料装置等多种技术,立体仓库与激光切割机采用总线数据通讯,通过自动编程软件为客户实现完整的加工流程。     

基于ABAQUS的锯齿形切屑形成机理分析与实验研究

锯齿形切屑的形成会导致机床振动,使刀具的切削性能下降,降低工件的加工质量,因此需要对其形成机理进行分析,合理优化切削参数,减少锯齿形切屑的形成机率。本文利用ABAQUS软件对钛合金的加工过程进行仿真分析,模拟锯齿形切屑的形成机理,并在不同切削条件下进行仿真和实验研究,讨论切削参数对切屑锯齿化程度的影响。结果表明,随着切削速度和进给量的增加,切屑的锯齿化程度逐渐增大,随着刀具前角的增大,切屑的锯齿化程度逐渐减小。研究结果对提高工件加工质量以及设计工艺参数有一定指导作用。     

Performance evaluation of chip breaker utilizing neural network

The continuous chip generated during turning operation deteriorates the workpiece precision and causes safety hazards for the operator. Appropriate control of the chip shape becomes a very important task for maintaining reliable machining process. In particular, effective chip control is necessary for a CNC machine or automatic production system because any failure in chip control can cause the lowering in productivity and the worsening in operation due to frequent stop. Therefore, a grooved chip breaker has been widely used for obtaining reliable discontinuous chips. In general, in order to develop a new cutting insert with a chip breaker, extensive time, research, and expense are required because several processes such as forming, sintering, grinding, and coating of products as well as different evaluation tests are necessary. In this study, the performance of commercial chip breakers was evaluated using a neural network that was trained through a back propagation algorithm. Important form elements (depth of cut, land, breadth, and radius) that directly influenced the chip formation were chosen among commercial chip breakers, and were used as input values of the neural network. As a result, the performance evaluation method has been developed and applied to commercial tools, which resulted in excellent performance. If the training data in the neural network is collected with greater consideration given to the effect of cutting conditions and the performance of chip breakers, it can be used for the design of chip breakers in the future.     

地轨式激光切割机分区除尘装置设计

本文介绍了一种地轨式激光切割机分区除尘装置,可高效抽除切割过程中产生的烟尘,很好地保护激光切割头,大大改善工作环境,提高激光切割机的使用效率。     

Vibration assisted scribing process on LCD glass substrate

A technique of vibration assisted scribing of LCD glass substrate is developed. In the paper a fundamental theory of vibration assisted scribing process is manifested. It is proposed that the rapidly varying periodical scribing load does not lead to as much an increase in the plastic deformation as that due to the servo controlled constant scribing load. Instead it mainly results in an increase in the elastic deformation. The induced elastic component would increase the median crack depth of the glass substrate. To verify the proposed theory, an additional piezoelectric actuator is implemented on the servo controlled loading mechanism of the scribing machine, and a periodically varying load superposed on the constant load is provided to the standard scribing wheel. Experimental results show that under a proper vibration frequency condition the median crack depth is significantly increased to about twice of that without vibration assisted scribing. Thus, the automatic separation of the glass without the need of breaking process similar to the case with the use of toothed wheel (penett) can take place. On the other hand, while the bending strength of the glass panel after scribing by toothed wheel is merely about half of that resulting from scribing by standard wheel, it remains almost unchanged by the developed technique.     

Development of a new rapid characterization method of hob's wear resistance in gear manufacturing—Application to the evaluation of various cutting edge preparations in high speed dry gear hobbing

Gear hobbing remains a cutting technology mainly dedicated to large-scale productions of gears for the automotive industry. The improvements in hobbing tool design are problematic due to the very long duration of wear tests and due to the application of special machine tools only available in production plants. In order to overcome these limitations and to accelerate the efficiency of the investigations, a new rapid testing method called “flute hobbing” has been developed on a standard five-axes milling machine widely present in research laboratories. This testing method has been associated with a software providing the geometry of each chip in hobbing. The correlation of the chip geometry with the wear of each tooth enables to discriminate the critical teeth of a hob in order to focus the development in this area of the cutting zone. This new methodology has been used to investigate the influence of the cutting edge preparation on the wear resistance of gear hobs made of PM-HSS in the context of dry high speed manufacturing. The application of the AFM technology to generate defined edge preparation has shown its efficiency to improve the tool wear resistance and has confirmed previous results.     

Water-assisted laser thermal shock machining of alumina

A combined experimental and computational approach was undertaken to investigate water-assisted laser cutting of 96% pure alumina specimens through controlled thermal shock fracture mechanism. A low-power CO₂ laser (<300 W) was used for localized heating and scribing of alumina samples followed by water quenching to induce thermal stress cracking. In order to elucidate the cutting mechanisms and identify the regime of processing conditions suitable for controlled fracture, laser cutting experiments were performed under two different environments: water-assisted laser cutting and dry laser cutting. Temperature profiles of the heat-affected zones were obtained using thermocouples and data acquisition system. Finite element analysis was applied to predict the temperature and thermal stress distributions developed during both water-assisted and dry laser cutting operations. Temperature histories of the samples recorded during cutting were compared with numerical model predictions to determine heat transfer parameters associated with wet and dry laser cutting of alumina samples. Both experimental data and numerical analysis indicate that water quenching makes a substantial difference in thermal stress distribution, which governs the ability to control the fracturing of alumina. This in turn, resulted in better control of cutting and higher feed rates than previously reported in laser machining of alumina.