基于球头铣刀车铣表面微观花纹研究

采用正交试验方法进行球头铣刀正交车铣加工硬铝工件材料的切削实验,确定车铣切削用量(铣刀转速、轴向进给量、每齿进给量、刀具齿数、加工深度和螺旋角等)对已加工表面微观花纹的影响。同时建立球头铣刀正交车铣已加工件表面微观花纹的数学模型,给出仿真步骤及算法流程,基于Fortran的主体计算程序和基于Matlab的后置处理程序对表面微观花纹进行仿真,比对表面微观花纹在切削实验与仿真的不同。     

基于Matlab的轴向车铣回转体工件表面微观形貌仿真

建立了描述轴向车铣回转体工件表面微观形貌的数学模型,并应用Matlab对表面微观形貌进行了仿真。结果表明,采用不同切削参数加工得到的回转体工件微观表面形貌会有很大差别。且选择适合的加工参数可在已加工表面得到良好的微储油结构。     

回转体内表面正交车铣加工仿真和分析

通过正交试验法设计9组正交试验L_9(3~4),以表面粗糙度为研究重点,对材料为7075铝合金的大型回转体内表面进行正交车铣加工,研究正交车铣加工大型回转体内表面时切削参数与表面粗糙度的关系。通过MATLAB软件对正交车铣加工大型回转体内表面的表面形貌进行仿真,将得到的仿真结果与试验结果进行对比分析,建立正交车铣加工大型回转体内表面的表面粗糙度计算公式。     

正交车铣高强度钢表面纹理的研究

针对58SiMn高强度钢材料,通过在改造的CE7132A仿形正交车铣机床上进行了一系列的正交车铣表面纹理试验,研究了正交车铣切削用量与表面纹理之间的关系,并且建立了正交车铣加工表面纹理方向角形成的数学模型,得到了纹理方向角与铣刀的轴向进给量和每齿进给量之间的函数关系式.     

正交车铣工件表面形成机理的研究

通过数学方法对正交车铣已加工表面的形成机理进行了详细的理论研究,给出了已加工工件理论微观圆度的计算方法和侧母线的数学表达式,由此分析了主要切削参数对理论微观圆度和工件侧母线形成的影响,并对加工圆柱表面时偏心量和轴向进给量的取值范围进行了详细阐述。     

单向铺层与织物结构CFRP端铣加工表面质量对比分析

对单向铺层与织物结构CFRP进行正交切削试验,对加工表面粗糙度进行方差分析,对加工表面宏观和微观形貌进行观察.结果表明,单向铺层CFRP表面粗糙度不受切削参数的影响,而每齿进给量是影响织物结构CFRP表面质量的显著因素,且表面质量随每齿进给量的增大而变差.单向铺层CFRP端铣加工表面会出现铺层间树脂形成的白色边界和斑块...     

基于车铣复合加工的已加工表面粗糙度分析

车铣复合加工是近些年来发展起来的先进的切削加工技术之一。本文采用正交实验方法,进行了正交车铣加工铝合金工件材料的切削实验,确定了车铣切削用量（铣刀转速、轴向进给量、每齿进给量等）与已加工表面粗糙度之间的关系。最后,通过正交实验法的方差分析进一步确定了各因素对表面粗糙度的影响及主次顺序。实验表明,铣刀转速（切削速度）和工件转速对表面粗糙度的影响较大。     

高架式五轴车铣加工中心的设计

针对现有大型薄壁回转体类零件加工存在的技术问题,提供一种结构简单、高效精密的高架式五轴车铣加工中心,并对其结构、结构特点、加工过程等问题作了详细论述.该加工中心的研制,解决了回转体类零件的高速车铣加工问题;尤其解决了内表面具有矩形网格结构的大型薄壁回转体零件的高速车铣加工问题.可实现一次装夹,就可完成复杂型面回转体大部分工序的一次整体高速精密加工.     

正交车铣TC4钛合金表面粗糙度分析

车铣加工技术是近年发展起来的先进切削加工技术之一。本文采用多因素正交试验法,进行了一系列的正交车铣TC4钛合金切削试验,研究了车铣切削用量与表面粗糙度之间的变化规律。通过方差分析确定了各因素对表面粗糙度的影响大小的主次顺序,每齿进给量和偏心量对表面粗糙度的影响较大。采用回归分析原理,建立了表面粗糙度的预测模型,根据统计检验结果表明,已加工表面粗糙度预测模型呈高度显著检验状态,具有很高的可信度。     

干式高速车铣铝合金已加工表面形成机理研究

高速车铣加工是一种新的先进加工技术,可望在干式条件下实现回转体零件的高速切削。本文主要研究干式条件下高速车铣铝合金时已加工表面的形成机理及影响因素。     

高速铣削铝合金叶片表面质量的试验研究

使用硬质合金球头铣刀对铝合金叶轮叶片进行了高速铣削试验。研究了切削速度和进给量对加工表面粗糙度的影响。试验结果表明:在高速加工中,每齿进给量比铣削行距对加工表面质量的影响更大;提高切削速度和减少每齿进给量有利于降低加工表面粗糙度。但当切削速度超过某一范围后,进一步提高速度对降低表面粗糙度的作用并不明显;每齿进给量减小到一定范围后,表面粗糙度反而会有所增加;对于铝合金叶片曲面的加工,合理选择切削速度、进给量和行距可获得较低的表面粗糙度值和较高的加工效率。     

Dynamic surface generation modeling of two-dimensional vibration-assisted micro-end-milling

An integrated model is proposed to simulate the surface generation in two-dimensional vibration-assisted micro-end-milling (2-D VAMEM). The model includes the developed submodels as dynamic cutting force model, machining system response model, and machined surface generation algorithm. The effects of feed rate on cutting force and surface roughness are investigated through simulations. It is found that the cutting force increases while the surface roughness decreases with the increment of the feed rate when the feed per tooth is smaller than the tool edge radius. The trials have been carried out to evaluate and validate the proposed model and the simulation results. The integrated model contributes to the comprehensive understanding of the process of machined surface generation in 2-D VAMEM and will assist the machining operators to select optimal machining parameters.     

铝合金高速切削表面粗糙度影响因素研究

为有效降低高速切削中铝合金的表面粗糙度值,通过多因素正交试验和单因素试验对各铣削参数进行研究,结果显示:各参数对铝合金表面粗糙度影响程度从大到小的顺序是:切削深度、主轴转速、每齿进给量、行距,且转速为18000r/min,每齿进给量为0.075mm,行距和每齿进给量一致,选择较小的切削深度时,在铝合金表面可获得较好的加工质量。     

基于UG的螺杆钻具转子正交车铣加工仿真

建立了描述螺杆钻具转子的数学模型,并实现了UG环境下的三维参数化建模。详细分析了采用正交车铣加工此类零件时的加工策略,并对仿真加工过程时主要参数的设置进行了具体阐述,实现了正交车铣钻具转子的仿真加工。结果表明,采用正交车铣完全可以取代传统的加工方法,实现了在通用机床上采用通用刀具完成螺杆钻具转子的加工,从而降低了零件的加工成本。     

Cutter workpiece engagement region and surface topography prediction in five-axis ball-end milling

Based on the machining tool path and the true trajectory equation of the cutting edge relative to the workpiece, the engagement region between the cutter and workpiece is analyzed and a new model is developed for the numerical simulation of the machined surface topography in a multiaxis ball-end milling process. The influence of machining parameters such as the feed per tooth, the radial depth of cut, the angle orientation tool, the cutter runout, and the tool deflection upon the topography are taken into account in the model. Based on the cutter workpiece engagement, the cutting force model is established. The tool deflections are extracted and used in the surface topography model for simulation. The predicted force profiles were compared to the measured ones. A reasonable agreement between the experimental and the predicted results was found.     

Surface topography and roughness of high-speed milled AlMn1Cu

The aluminum alloy AlMn1Cu has been broadly applied for functional parts production because of its good properties. But few researches about the machining mechanism and the surface roughness were reported. The high-speed milling experiments are carried out in order to improve the machining quality and reveal the machining mechanism. The typical topography features of machined surface are observed by scan electron microscope(SEM). The results show that the milled surface topography is mainly characterized by the plastic shearing deformation surface and material piling zone. The material flows plastically along the end cutting edge of the flat-end milling tool and meanwhile is extruded by the end cutting edge, resulting in that materials partly adhere to the machined surface and form the material piling zone. As the depth of cut and the feed per tooth increase, the plastic flow of materials is strengthened and the machined surface becomes rougher. However, as the cutting speed increases, the plastic flow of materials is weakened and the milled surface becomes smoother. The cutting parameters (e.g. cutting speed, feed per tooth and depth of cut) influencing the surface roughness are analyzed. It can be concluded that the roughness of the machined surface formed by the end cutting edge is less than that by the cylindrical cutting edge when a cylindrical flat-end mill tool is used for milling. The proposed research provides the typical topography features of machined surface of the anti-rust aluminum alloy AlMn1Cu in high speed milling.     

Three-dimensional stability prediction and chatter analysis in milling of thin-walled plate

Stability lobe diagram can be used for selecting proper milling parameters to perform chatter-free operations and improve productivity during milling of thin-walled plates. This paper studies the machining stability in milling of thin-walled plates and develops a three-dimensional stability lobe diagram of the spindle speed, tool position, and axial depth of cut. The workpiece-holder system is modeled as a 2-degree-of-freedom system considering that the tool system is much more rigid than the thin-walled plate, and dynamic equations of motion described for the workpiece-holder system are solved numerically in time domain to compute the dynamic displacements of the thin-walled plate. Statistical variances of the dynamic displacements are then employed as a chatter detection criterion to acquire the stability lobe diagram. The experimentally obtained stability limits correspond well with the predicted stability limits. In addition, influence of feed rate on stability limits is also investigated. By performing frequency analysis of the measured cutting forces to judge if chatter occurs, it is found that feed per tooth has little influence on the stability limits. However, feed per tooth impacts the machined surface quality. The results show that the surface quality drops by increasing feed per tooth.     

基于车铣复合中心的针阀接头数控加工

介绍了车铣复合中心加工针阀接头零件新工艺,重点分析了加工难点工艺过程,解决了普通数控加工方法对于精密零件加工精度、效率低和工序分散问题,为符合现代制造技术发展方向的车铣复合加工推广和应用提供参考和借鉴.