超声振动铣削碳纤维复合材料铣削力的试验研究

采用多因素正交试验法对碳纤维复合材料进行超声铣削和普通铣削的加工试验,研究了在不同切削参数下该材料铣削力的变化规律,使用Kistler测力仪对本试验进行测量,得到了铣削速度、每齿进给量、切削深度对铣削力的影响规律.研究结果表明:随着铣削速度、每齿进给量、铣削深度的增加,两种铣削方式下的铣削力都随之增加,但超声铣削产生的铣削力低于普通铣削产生的铣削力.     

反应高能球磨制备纳米WC/MgO复合粉末

将WO3、C和Mg粉末按摩尔比为1∶1∶3混合,在室温下用高能球磨法对其进行球磨,经XRD、SEM和TEM分析表明,在球磨到4.7 h时,WO3、石墨和镁之间发生氧化还原反应直接生成了WC和MgO粉末,之后随球磨时间的延长,粉末不断细化.球磨50 h后,得到WC晶粒度和颗粒度分别约为25 nm和100 nm的WC/MgO复合粉末.实验结果和热动力学分析表明,WC/MgO的合成是一个自蔓延反应过程,此反应可以在很短的时间内完成.     

应用小波研究动态铣削力及预报铣削颤振

在铣削条件下,利用PC I-1712高速数据采集卡进行数据采集,应用小波分析进行数据处理,分析研究了铣削力信号的分解与重构,根据铣削力的主要频率,得到不同频带重构的动态铣削力信号,通过分析重构后的动态铣削力信号,发现产生了铣削颤振,并依据动态铣削力信号概率密度的变化预报颤振原则证明了铣削过程产生了铣削颤振现象,因而可以利用动态铣削力的变化初步预报铣削颤振.     

基于铣削力突变的拼接模具硬态铣削工艺优化

针对刀具磨损过快和加工稳定性下降的问题,进行了淬硬钢Cr12MoV拼接模具铣削过程中铣削参数和路径优化的研究.通过试验研究揭示了刀具铣削方向、切削速度、进给速度及切削深度对拼接处铣削力突变的影响规律,并借助多因素试验得到了铣削条件对铣削力突变影响的主次因素.为降低铣削力突变对铣削过程的影响,以铣削力突变最小为目标进行了正交试验研究,并在此基础上得到了优化后的铣削参数组合.研究成果可为拼接模具铣削工艺优化提供有意义的参考.     

基于PRO/ENGINEER的螺旋立铣刀刀体建模

针对刀具生产企业在产品设计中仍然采用二维方法,效率低下且缺乏直观性的问题,创建了基于PRO/TOOLKIT参数化设计所需的可转位螺旋立铣刀刀体模型,应用PRO/ENGINEER软件对该类型刀具刀体进行三维建模,对于建模中的难点———刀片槽的建模提供了2种不同的解决方法并进行比较,所得模型已应用于参数化设计中。     

管电极微细电火花铣削加工

提出了采用对轴向损耗不敏感的微细管电极进行微细电火花分层铣削的加工方法,并对管电极在加工过程中的损耗特性进行了理论分析。在此基础上,分别采用铜管电极和实心电极进行了微细电火花铣削加工实验。结果表明:采用中空结构的管电极不仅减小了铣削过程中电极端部的损耗半径,提高了加工精度,而且简化了微细电火花铣削的分层策略和电极损耗补偿策略。     

Theoretical modeling of cutting temperature in high-speed end milling process for die／mold machining

A parametric model of cutting temperature generated in end milling process is developed according to the thermal mechanism of end milling as an intermittent operation, which periodically repeats the cycle of heating under cutting and cooling under noncutting. It shows that cutting speed and the tool-workpiece engagement condition are determinative for tool temperature in the operation. The suggested model was investigated by tests of A1TiN coated endmill machining hardened die steel JIS SKD61, where cutting temperature on the flank face of tool was measured with an optical fiber type radiation thermometer. Experimental results show that the tendency of cutting temperature to increase with cutting speed and engagement angle is intensified with the progressing tool wear.     

Choice of reference surfaces for machined surface roughness in milling of SiC_p/Al composites

In order to choose the appropriate reference surface on the machined surface roughness of Si Cp/Al composites, the cutting experiments of Si Cp/Al composites were carried out, and the machined surface topography was measured by OLS3000 Confocal laser scanning microscope. The 3D measured data of machined surface topography were analyzed by the area power spectrum density. The result shows that the texture of machined surface topography in milling of Si Cp/Al composites is almost isotropic. This is the reason that the values of Rq at different locations on the same machined surface are obviously different. Through the comparison of performance of different filtering methods, the robust least squares reference surface can be used to extract the surface roughness of SiC p/Al composites effectively.     

最佳铣削用量的选择

以端铣刀铣削钢体为例 ,提出了通过计算机优化设计选择最佳铣削参数的方法 ,达到了提高生产率、降低加工成本的目的。     

旋风铣削螺纹梳形铣刀的研究

旋风铣削螺纹是一种先进的高效率加工方法，已广泛应用在药筒生产中，本文在理论研究和设计实现的基础上，对螺纹梳形铣刀的主要设计加工问题进行了研究，提出了有关经验公式和参数值。     

Dry face milling of titanium alloys

In machining titanium alloys, cutting tools generally wear out very rapidly because of the high cutting temperature resulted from the low thermal conductivity and density of the work material. In order to increase the tool life, it is necessary to suppress the cutting heat as much as possible by applying an abundant amount of coolant, but this will entail serious techno-environmental and biological problems. To study the performance and avoid these limitations, a PVD-coated insert was used to the dry face mill of (α β) titanium alloys. As a result it was found that the inserts exhibit an excellent cutting performance at low cutting speeds and feed rates, and there is no significant difference in the dominant insert failure mode between the wet and dry cutting in discontinuous cutting.     

Robotic milling for rapid ceramic prototyping

Robotic milling is a developing method for rapidly producing prototypes and parts, but the application is limited for materials such as wax, wood, plastic and light metal, etc. The reason for this is because of the robotic weak rigidity. In this paper, a method of robotic milling for ceramic prototyping is developed, one that has been successfully applied in a new rapid hard tooling technology-Direct Prototype Spray Tooling. At first, the appropriate ceramic materials mixed with metal powder are confirmed for the robotic milling and the following plasma spraying process. Then the 6 - DOF robotic milling paths are extracted from the NC code and transformed into the robotic JBI type file, the NC code generated through the general CAD/CAM software such as UG -NX. Finally, the robotic milling characteristics such as moving path accuracy and milling force are tested to find the best milling parameters and to ensure the executable, accurate and efficient ceramic prototype milling technology. The development of this method not only broadens the robotic milling material range but also extends the rapid prototyping fields. It can also be used for producing ceramic parts that are difficult to machine.     

零件铣削加工表面质量研究

利用正交实验原理进行实验设计并对实验结果进行回归分析,建立了高速钢球头铣刀铣削45钢时表面粗糙度的预测模型并对该模型的回归方程进行了显著性检验,证明该模型具有较高显著性,结论为利用CAM软件进行自动编程加工时切削参数的优选提供了依据.     

Robotic milling for rapid ceramic pototyping

Robotic prototyping is an active research directionof the industrial robot,which has focused on roboticmilling for rapid prototyping and parts.Joris S.M.etal.developed a sculpturing robot system for millinglight metal and polyurethane material[2].W.C.Tse etal.adopted a six-DOF industrial robot to mill foam orwax prototype directly[3~5].Shin-ichi Matsuoka usedrobotic high speed milling to machine a thin workpieceof aluminum alloy[6].Compared with the general nu-merical control machine,the i…     

Novel spin glasses by mechanical milling

Novel spin-glass alloys were synthesized by milling intermetallic compounds and also by milling mixtures of crystalline elemental powder in a high-energy ball mill.Spin glass behaviour was found in amorphous Co2Ge,which was amorphised by milling in mechanically disordered crystalline GdAl2 in ball-milled crystalline and amorphous CoZr,and in mechanically alloyed Co-Cu,which formed a supersaturated f.c.c.solid solution.All these materials are binary alloys and tlie concentration of the magnetic element is high,which makes them novel types of spin glasses.It is shown that ball milling may not only lead to structural metallic glasses,but can also generate the magnetic pendant of a structural glass,namely the spin glass.     

Optimization strategy in end milling process for high speed machining of hardened die/mold steel

1. Introduction The introduction of advanced cutting tools like AlTiN-coated micro-grain carbide end mill since the 1990s has changed the trend in die/mold manufacturing towards hard machining both in roughing and finishing [1]. Nowadays, high speed machi…     

硬质合金倒角铣刀的优化设计

针对大型电站设备制造中难加工材料及复杂零件的加工过程中刀具破损严重的问题，进行了硬质合金倒角铣刀的优化设计。在设计过程中，优选了刀具几何参数；用向量矩阵法进行刀具角度变换计算，从而确定了刀槽的空间位置；并利用I-deas软件进行了三维实体造型设计。     

四坐标侧铣加工中的误差分析

首先将四坐标侧铣加工存在的加工误差分为由四坐标加工自身的局限性引起的误差和法矢异向误差两种,然后分别对这两种误差的产生原因进行了分析并给出了计算公式,另外还给出了法矢异向误差沿直母线方向的分布并提出了一种减小法矢异向误差的算法.     

基于物理学的铣削过程仿真关键技术

为了预测零件加工变形，基于铣削加工有限元理论，构建了基于物理学的铣削加工过程仿真环境，研究了刀位轨迹离散、材料去除、网格自适应生成及动态网格数据维护等关键技术的处理.针对刀具的每次进给运动，系统自动检测刀具和工件毛坯网格相交的区域，通过网格自适应求精、粗化和删除以及有限元分析计算，模拟真实的铣削加工过程.该仿真环境可综合考虑加工参数、刀具路径等因素对零件加工变形的影响，优化加工工艺，保证加工精度.     

Smoothness-oriented path optimization for robotic milling processes

Industrial robots are increasingly used for five-axis machining operations, where the rotation of the end effector along the toolaxis direction is functionally redundant. This functional redundancy should be carefully resolved when planning the robot path according to the tool path generated by a computer-aided manufacturing(CAM) system. Improper planning of the redundancy may cause drastic variations of the joint motions, which could significantly decrease the machining efficiency as well as the machining accuracy. To tackle this problem, this paper presents a new optimization-based methodology to globally resolve the functional redundancy for the robotic milling process. Firstly, a global performance index concerning the smoothness of the robot path at the joint acceleration level is proposed. By minimizing the smoothness performance index while considering the avoidance of joint limits and the singularity and the constraint of the stiffness performance, the resolution of the redundancy is formulated as a constrained optimization problem. To efficiently solve the problem, the sequential linearization programming method is employed to improve the initial solution provided by the conventional graph-based method. Then, simulations for a given tool path are presented. Compared with the graph-based method, the proposed method can generate a smoother robot path in which a significant reduction of the magnitude of the maximum joint acceleration is obtained, resulting in a smoother tool-tip feedrate profile. Finally, the experiment on the robotic milling system is also presented. The results show that the optimized robot path of the proposed method obtains better surface quality and higher machining efficiency, which verifies the effectiveness of the proposed method.