飞机蒙皮镜像铣加工稳定性分析

镜像铣技术是近年来提出的一种针对大尺寸薄壁件的加工方法,其加工环保、高效,具有逐步取代传统化铣加工的趋势。针对飞机蒙皮镜像铣加工过程中的颤振问题,首先,根据镜像铣加工特点,建立工艺系统颤振稳定性极限的预测模型;其次,通过有限元方法对蒙皮工件进行模态分析,分析蒙皮不同加工位置动力学特性变化导致的铣削稳定性变化,并通过实验测量获取工件动力学参数,对不同加工位置的稳定性做出预测;最后,开展加工实验,基于非接触测量方法,在线监测镜像铣加工区域的振动位移,通过时、频域信号对加工状态进行辨识,揭示了镜像铣加工过程的稳定性变化及失稳机制,验证了所提方法的准确性,在工程领域具有较高的实用价值。     

燃料组分差异对贫油熄火边界的影响

为了推进替代燃料的多元化,扩大航空燃料的组分分布。以标准航空煤油为基准,研究了柴油和高沸点费托油对燃烧室贫油熄火边界的影响。实验采用单头部燃烧室,通过改变燃烧室进出口压力,研究其熄火边界的变化规律,并分析了其与理化性质和组成的关联关系。结果显示在220kPa的出口压力下,航空煤油的熄火性能略优于另外两种燃油,高沸点费托油相比航空煤油熄火边界窄5%,而在140kPa的低压条件下,高沸点费托油的熄火边界相比航空煤油拓宽了8%。分析得到整体上低沸点烷烃和直链烷烃的熄火性能较好。      

Framework and development of data-driven physics based model with application in dimensional accuracy prediction in pocket milling

In the manufacturing of thin wall components for aerospace industry, apart from the side wall contour error, the Remaining Bottom Thickness Error (RBTE) for the thin-wall pocket component (e.g. rocket shell) is of the same importance but overlooked in current research. If the RBTE reduces by 30%, the weight reduction of the entire component will reach up to tens of kilograms while improving the dynamic balance performance of the large component. Current RBTE control requires the off-process measurement of limited discrete points on the component bottom to provide the reference value for compensation. This leads to incompleteness in the remaining bottom thickness control and redundant measurement in manufacturing. In this paper, the framework of data-driven physics based model is proposed and developed for the real-time prediction of critical quality for large components, which enables accurate prediction and compensation of RBTE value for the thin wall components. The physics based model considers the primary root cause, in terms of tool deflection and clamping stiffness induced Axial Material Removal Thickness (AMRT) variation, for the RBTE formation. And to incorporate the dynamic and inherent coupling of the complicated manufacturing system, the multi-feature fusion and machine learning algorithm, i.e. kernel Principal Component Analysis (kPCA) and kernel Support Vector Regression (kSVR), are incorporated with the physics based model. Therefore, the proposed data-driven physics based model combines both process mechanism and the system disturbance to achieve better prediction accuracy. The final verification experiment is implemented to validate the effectiveness of the proposed method for dimensional accuracy prediction in pocket milling, and the prediction accuracy of AMRT achieves 0.014 mm and 0.019 mm for straight and corner milling, respectively.     

Loop细分曲面精加工刀具轨迹生成

细分曲面既能表示连续的几何设计模型也能表示离散的加工模型,避免了模型转换的复杂中间过程.细分曲面除了对于构造具有任意拓扑结构的复杂零件具有巨大的优势外,对于数字化制造也极具发展潜力.因此,对基于Loop细分曲面的精加工刀具轨迹生成算法进行了研究.首先利用基于弦长误差的自适应插值Loop细分得到精加工模型;然后利用等斜率跟踪法将精加工模型分割为平坦区域和非平坦区域.对各个区域依次进行处理,不同区域实施不同的刀具轨迹规划.据此,既避免了因细分过程数据量过大而导致的曲面精度不足或表面质量降低的问题,又可顺利计算整张曲面相对均匀残留高度的刀具轨迹.最后,为验证该算法的可行性进行铣削加工实验.      

镜像铣削加工奇异区域刀具路径优化

在大型薄壁件镜像铣削加工中,由奇异点引起的旋转轴运动不连续会影响加工质量,降低加工效率。针对此问题,分析了镜像铣削加工奇异点存在的原因,提出了一种奇异区域内的刀具路径优化方法。首先,针对镜像铣削系统的铣削头和支撑头分别建立了其旋转轴运动学变换模型,推导旋转轴微分运动关系,据此分析奇异点存在的原因及其对加工质量和效率的影响,定义了机床行程内的奇异区域范围。分析结果表明在镜像铣削系统行程范围内,仅铣削头存在奇异区域,而支撑头不存在奇异区域。然后,在镜像铣削加工刀路约束条件下,基于刀路光顺性指标建立了刀路优化模型。通过在加工曲面参数域内对跨越铣削头奇异区域的刀路进行调整,使得优化后的刀路更加光顺,以提高加工精度和表面质量,减少奇异区域附近的加工时间。最后,通过镜像铣削加工实验验证所提方法的有效性。     

Laser-induced oxidation assisted micro milling of high aspect ratio microgroove on WC-Co cemented carbide

Severe tool wear and poor surface quality are the main problems during micro machining of cemented carbide. In this work, an innovative hybrid process of laser-induced oxidation assisted micro milling (LOMM) was proposed to solve the problems. A nanosecond laser was utilized to induce oxidation of the WC-20%Co material, producing loose oxide which was easy to remove. The micro machinability of the material was improved by laser-induced oxidation. The oxidation mechanisms of cemented carbide were studied. A microgroove with a depth of 2.5 mm and aspect ratio of 5 was fabricated successfully. The milling force, surface quality and tool wear mechanisms were investigated. For comparison, a microgroove was also fabricated with conventional micro milling (COMM) using identical milling parameters. Results revealed that in LOMM the milling force and tool wear rate were extremely low during removing the oxide. The machined surface quality and dimensional accuracy achieved by LOMM were superior to those obtained by COMM. The surface roughness S_a of the microgroove bottom reached 88 nm in LOMM, while the cross-sectional geometry of the microgroove was a trapezoid. Perpendicularity of the microgroove sidewall machined by LOMM was better than that by COMM. The tool wear forms in LOMM were coating spalling and slight tool nose breakage. Compared with COMM, the tool life in LOMM was prolonged significantly. It indicates that the proposed hybrid process is an effective and efficient way to fabricate high aspect ratio micro-features with high dimensional accuracy.     

气体流场对C／C复合材料CVI致密化效果的影响

以丙烯为碳源气体,研究平板针刺预制体在不同倾斜角放置和不同进气方式条件下化学气相渗透（ CVI）工艺制备C／C复合材料的致密化效果。采用工业CT、浸泡介质法和偏光显微镜对沉积样品的密度分布、开孔孔隙率和织构分别进行表征。沉积102 h后,倾斜17°、前进气条件下试件的密度最高,达到1．45 g／cm－3。结果表明,试样由底端到顶端的密度是有小幅递增的,开孔孔隙率是逐渐减小的。4块试件热解炭的织构以光滑层为主,试样消光角的测量结果表明直立状态和倾斜17°、后进气状态热解炭织构取向度从底部到顶端有增大的趋势,这种织构的增长趋势与锥形回转体扩张段的材料设计相符合。     

沉积温度对CVD-SiC涂层显微结构的影响

介绍了采用化学气相沉积（CVD）方法在C/SiC复合材料表面制备SiC抗氧化涂层的情况.对不同工艺条件下制备出的SiC涂层,使用SEM,EDS和XRD分析了沉积层的物相和显微结构.结果表明：SiC涂层生长速度随沉积温度升高而升高,晶粒尺寸也随之增大;在较高沉积温度下,可以产生较大的沉积速度,但SiC涂层表面粗糙度将会增大.     

定长补偿电火花铣削加工中锥形电极的形成及稳定性

电火花铣削可以利用简单电极加工复杂工件,对铣削过程中电极损耗进行补偿是保证工件加工精度的重要措施。使用圆柱电极进行定长补偿铣削加工,加工过程中电极端面会形成一个圆锥形。为保证补偿精度,对电极圆锥形端面的形成及稳定性进行了研究。通过对定长补偿下工件被加工情况的研究,阐述了圆锥形电极形成的具体过程;并且论证了在加工进入稳定阶段以后,圆锥端面角度会基本保持在一个恒定值,研究了初始加工深度和补偿长度对锥形过渡阶段的影响;在电极直径、电参数一定情况下,验证了加工模型中锥形角度与目标加工深度的函数关系,实验结果与模型计算结果相差2.1%;最后给出了加工实例,并获得较好的加工效果。     

RP-3航空煤油着火特性的实验

在化学激波管中利用反射激波着火,采用壁面压力与OH自发光作为着火指示信号,测量了着火温度范围为1100~1600K,压力为0.1,0.2,0.3MPa,当量比为0.5,1.0,1.5时RP-3航空煤油/氧气/氩气混合气的着火延迟时间,分析了着火温度、压力以及当量比对混合气着火延迟时间的影响,并拟合得到了不同压力与当量比下混合气着火延迟时间的Arrhenius关系式.结果表明:在不同压力与当量比下,混合气的着火延迟时间的对数与着火温度的倒数呈线性关系,同时,随着着火温度与压力的升高以及混合气当量比的降低,着火延迟时间逐渐缩短.