用快速造型技术生产金属零件的方法及评价

比较几种典型的快速原型制造（ＲＰＭ）方法的特点，分析和评价它们用于生产金属零件的可能途径以及需要解决的问题；叙述用各种快速成形的原型生产金属零件的技术路线及其适合的零件种类。认为快速成形技术与铸造技术相结合是由快速成形转化为金属零件的最佳途径；在快速制造原型的问题基本解决以后，为快速铸造和类金属零件，需解决的问题是研究和探索适应各种快速成形方法的铸造工艺及材料．     

COMPARISON OF MACHINED SURFACE QUALITY OBTAINED BY HIGH-SPEED MACHINING AND CONVENTIONAL TURNING

The aim of this article is to present some results of investigations on machined surface quality produced by high-speed cutting technologies and conventional turning. Machined surface quality demands significantly affect cost of production and increase the price of a product. Hence, obtaining a good quality of surface while lowering production costs has been metalworkers' preoccupation since beginning their jobs. One possible approach for solving that problem is introducing high-speed machining facilities into production. High-speed machining allows higher productivity, excellent surface finish and good dimensional accuracy in the manufacturing process. Therefore these technologies have considerable advantages over traditional machining technologies. In this article some high-speed machining tests on different materials with different hardness, different machinability index, and by using different experimental approaches have been illustrated. Hard turning and high-speed turn milling, in particular, have been analyzed from the aspect of applicability of these technologies on conventional machines, since these machines still can be found in many manufacturing facilities. Results obtained through these experiments confirmed advantages of high-speed technologies over conventional machining. It has been shown that common production machines, e.g., a universal lathe, in combination with new cutting tools, might be use effectively in some high-speed applications also.     

高速切削刀具材料及其应用

高速切削能加工出精度较高的零件,还能降低加工成本。高速切削技术已经成为最有前途的先进制造技术之一,其应用领域正在持续扩展。高速切削技术是随着刀具技术如刀具材料等的发展而发展起来的。介绍了高速切削中所使用的金刚石、立方氮化硼、陶瓷、金属陶瓷和涂层刀具等的性能、适用范围和发展方向,并介绍涂层刀具、超细晶粒硬质合金和高速钢刀具的制备技术,以促进高速切削技术的推广应用。     

COMPARISON OF MACHINED SURFACE QUALITY OBTAINED BY HIGH-SPEED MACHINING AND CONVENTIONAL TURNING

The aim of this article is to present some results of investigations on machined surface quality produced by high-speed cutting technologies and conventional turning. Machined surface quality demands significantly affect cost of production and increase the price of a product. Hence, obtaining a good quality of surface while lowering production costs has been metalworkers' preoccupation since beginning their jobs. One possible approach for solving that problem is introducing high-speed machining facilities into production. High-speed machining allows higher productivity, excellent surface finish and good dimensional accuracy in the manufacturing process. Therefore these technologies have considerable advantages over traditional machining technologies. In this article some high-speed machining tests on different materials with different hardness, different machinability index, and by using different experimental approaches have been illustrated. Hard turning and high-speed turn milling, in particular, have been analyzed from the aspect of applicability of these technologies on conventional machines, since these machines still can be found in many manufacturing facilities. Results obtained through these experiments confirmed advantages of high-speed technologies over conventional machining. It has been shown that common production machines, e.g., a universal lathe, in combination with new cutting tools, might be use effectively in some high-speed applications also.     

淬硬钢的高速切削加工

淬硬钢以其优良的使用性能在模具行业中占着非常重要的地位，随着高速加工中心在我国的应用的增加，高速加工已成为淬硬钢管等高硬度材料切削加工的主要手段。本文首先介绍了淬硬钢高速加工的概况，针对使用涂层刀具淬硬钢时出现的具体问题，结合实际研究分析了切削刀具，加工工艺参数和走刀方式等对加工过程的影响，并提出一些实际加工中应注意的问题，改善加工条件和提高加工质量的方法。     

Rapid and cost-effective manufacturing of high-integrity aerospace components

This paper presents a comprehensive set of theoretical investigations and industrial applications of computer-based rapid manufacturing technology for high-integrity aerospace components. Two rapid manufacturing processes have been proposed by integrating rapid prototyping, high-speed machining (HSM), reverse engineering and geometric computation theory. They have been validated through trial manufacturing of a matrix of current aerospace components embracing critical design features to be found across the aerospace industry. Applied to future development programmes, this research will provide aerospace companies the benefits of significant decrease in product introduction lead-time, savings in non-recurring product introduction costs and considerable reduction in manufacturing costs for “one off” and low volume service parts. The findings can also be applied to rapid prototype development in other industries, such as automotive and military.     

A finishing cutter selection algorithm for additive/subtractive rapid pattern manufacturing

The additive/subtractive rapid pattern manufacturing (RPM) process sequentially deposits thick material slabs and then machines them into desired geometries in a layer-by-layer manner. Although most rapid manufacturing systems mainly intend to increase flexibility in manufacturing rather than to reduce processing speed, it is still practical to choose the optimized sets of cutters and machining parameters specifically for each layer to improve both the machining quality and efficiency. This paper presents an algorithm to automatically select finishing cutter geometry, diameter, and calculate machining parameters for the RPM process. Inputs to this algorithm are StereoLithography file from a computer-aided design model and a cutter library. Finishing cutter selection is based on geometry accessibility and machining process efficiency analysis. The algorithm has been implemented in RPM automatic process planning software and the experimental result on a sample part is presented to show the efficacy of this algorithm.     

高速加工技术对我国制造业的影响

进入20世纪以来，作为先进制造技术中重要部分的高速加工解决了传统加工方法所遇到的问题，此加工方法有着自己独特的特点，已经成为现代工业不可缺少的方法和手段，对我国的制造业正产生着越来越重要的影响。     

大型GCr15丝杠高速硬旋铣多尺度有限元建模关键技术研究

高速硬旋铣加工技术正成为大型螺纹件加工的重要手段,但该工艺加工机理研究的滞后制约了其加工性能的进一步提升.综合分析高速硬旋铣工艺的工件材料特性、切削运动过程和工艺参数,对GCr15的高速切削本构模型、切屑分离、刀屑界面特性、刀具磨损、工装结合面特性和刀盘动态特性等高速硬旋铣跨尺度有限元建模技术进行了剖析,规划设计了该工艺的FEM模型.     

快速成形集成制造系统的开发与研究

快速成形制造系统以快速成形技术的核心技术,实现ＣＡＤ／ＲＥ、ＲＰ、ＲＴ的技术集成。西北ＲＰＭ应用服务中心以西安交通大学为技术依托,在工艺集成、系统精度、数据集成、远程网络化服务等方面进行研究与开发。以实际案例说明快速成形技术及以其为基础的快速模具技术在企业新产品的快速开发中的重要作用。     

Positional correction algorithm of a laser galvanometric scanning system used in rapid prototyping manufacturing

The laser galvanometric scanning technique has brought rapid prototyping manufacturing into a new era. However, a number of errors severely affect the prototyping accuracy of the work piece. This paper gives a detailed analysis of the errors involved in the galvanometric scanning system used in rapid prototyping manufacturing. A positional correction algorithm has been developed to rectify the errors to meet the precision requirements of the processing. Experimental results based on a selective laser stinting (SLS) machine prove the efficiency of the positional correction algorithm.     

超高速铣削表面特征的研究

利用扫描电镜对超高速加工中心超高速铣削的试样的表面特征进行研究,并对加工状态进行监控,通过扫描电镜获得高速铣削表面质量的情况,用X射线能谱分析装置对扫描电镜得到的数据进行分析并与普通加工比较,从而找出超高速加工时影响表面质量的因素,找到一种使高速铣削工件表面质量提高、加工参数优化的方法。     

Selection of the Machining Inclination Angle in High-Speed Ball End Milling

High-speed machining is a key issue for current die and mould manufacturing. Though this technology has great potential for high productivity, tool wear accelerated by high cutting speeds and hard materials is a barrier. In this work, we attempted to reduce tool wear by controlling the machining inclination angle between the tool and the workpiece. To do this, the range of cutting angles engaged in the cutting using a ball end cutter is obtained from the boundary lines describing machined sculptured surfaces represented by the cutting envelop condition and the geometric relationships of successive tool paths. Then, the chip cross-sectional area and chip length can be obtained from the calculated cutting edge and the rotational engagement angle. The simulation results showed that a machining inclination angle of 15° was good enough from the point view of machineability, and this value was verified by a cutting experiment using high-speed ball end milling.     

航空发动机整体叶轮快速制造的试验研究

选择性激光烧结与铸造技术相结合 ,是快速制造金属零件的有效途径。本文介绍了利用这种技术制作整体叶轮铸造型腔 ,并通过铸造快速获得整体叶轮零件的工艺试验     

A new method for heat measurement during high speed machining

The cutting temperature and temperature distribution along the rake face of cutting tool and work piece is an essential factor in study of machining processes due to its effect on surface quality, tool life, tolerances, metallurgical behavior and chip-removing rate. Several methods have been introduced to measure temperature during machining, such as the thermocouple technique, infrared camera and metallurgical methods. Each of these methods has some advantages and limitations. In this article, an infrared high-speed sensor with specially designed software has been used to measure the transferred heat to the work piece during high speed machining (HSM) of bronze alloys. The results revealed that this system enhances accuracy and reduces the number of tests required.     

190柴油机曲轴数控铣削加工的分析探讨

曲轴是发动机的主要零件,其加工质量和加工效率直接影响发动机的工作性能和制造。曲轴粗加工采用CNC外铣加工工艺,使工件的加工精度、适应多品种生产的柔性和质量的稳定性都有了明显的改善。我厂引进了两台数控曲轴外铣铣床,特别适合于那些对平衡块侧面需要加工、轴颈没有沈割槽的曲轴。其较之车削、内铣等工艺,具有更高的生产效率。以济柴190型柴油机曲轴加工为实例,简要讲述了用数控曲轴铣床进行曲轴粗加工、半精加工的铣切工艺过程步骤和优点。     

基于PowerMILL的高速切削数控编程策略与应用研究

高速切削是世界制造业中的一项综合性的高新技术。从高速切削的特殊工艺性与自动控制的复杂性出发,阐述了PowerMILL软件所具有的经典加工策略,并通过具体实例研究和分析了基于PowerMILL软件的高速切削NC编程思路、操作方法、工艺处理、NC代码的编辑和调试,实现了一体化作业,更好地适应现代工程需要。     

高速加工理论在普通数控机床上的应用

高速加工在切削速度、材料去除率以及表面加工质量等方面较普通数控加工具有明显优势。在工艺研究中,将高速加工切削理论应用在现有的普通数控设备上,在主轴转速不变或相应提高的情况下,提高切削移动速度同时减小切削深度进给量,从而达到提高切削效率、减小切削应力以及改善加工表面质量的目的。     

An experimental evaluation of the capabilities of a fluidised-bed fixturing system

A phase-change fixture is a single adaptive device which can hold parts of various shapes and sizes while they are subjected to a wide variety of manufacturing operations. In this paper, a fundamental experimental investigation of adaptable fluidised-bed phase-change fixturing systems is presented. The results of this experimental investigation, which focuses on evaluating the ability of these fixtures to resist complex combinations of axial, bending and torsional loads, have provided estimates of the fixturing capability of this class of fixtures. This work has precipitated the development of a semi-automated hydraulically-operated prototype fixturing system, which is currently being employed to fixture parts of various shapes and sizes for several diverse manufacturing tasks, including metal-cutting operations, on a horizontal-axis LeBlond-Makino MC65-A60 machining centre.     

微型刀具在高速加工中心上的应用

微型刀具应用在高速加工中心上是21世纪的一项高新技术。高速切削加工以高效率、高精度和高表面质量为基本特征,在机械制造行业获得了越来越广泛的应用,并已取得了重大的经济效益,是当代先进制造技术的重要组成部分。本文结合Datron高速加工中心,配以Datron刀具,介绍了高速加工的原理、实现高速加工所应具备的条件以及高速加工所带来的优越性。