Design and development of a five-axis machine tool with high accuracy,stiffness and efficiency for aero-engine casing manufacturing

In order to satisfy the machining requirements of aero-engine casing in modern aviation industry, this paper investigates three main issues during the design and development process of a five-axis machine tool with high accuracy, stiffness and efficiency, including whole structure design,key components design, and supporting stiffness design. First, an appropriate structure of five-axis machine tool is determined considering the processing characteristics of aero-engine casing. Then, a dual driv...     

CF/PEEK复合材料超声辅助铣削力和表面质量研究

为改善碳纤维增强聚醚醚酮复合材料（CF/PEEK）在铣削加工时所产生的毛刺、分层以及表面凹坑等缺陷，采用超声辅助铣削的加工方式分别沿0°、45°、90°、135°四种纤维方向角对CF/PEEK进行实验，并与传统铣削进行对比研究。结果表明：超声辅助铣削与传统铣削相比，切削力更小且加工质量更优。沿90°纤维方向角对试件进行超声辅助铣削，切削力、表面粗糙度和毛刺高度降幅最显著，分别降低了16.79%、28.9%和71.9%。而且在相同的加工参数下，超声辅助铣削与传统铣削相比，能够有效地改善表面凹坑、分层等表面缺陷。     

分体组合式双自由度对日定向系统构型及布局设计

为解决空间站在不同的构型及飞行姿态下，因太阳入射角变化大引起的太阳电池翼难以对日定向的难题，提出分体组合式双自由度对日定向系统构型。研究空间站构型及飞行姿态，确定采用A轴与B轴2个轴独立运转、单独控制的对日定向方式，2个轴通过桁架结构实现正交连接。在梦天实验舱单舱飞行时，A轴不动，B轴根据轨道周期跟踪太阳，通过飞行器姿态调整补偿太阳入射角的变化。组合体飞行时，B轴补偿太阳高度角，A轴根据轨道周期带动B轴与太阳电池翼共同跟踪太阳，实现双自由度对日定向。在轨飞行结果表明:在不同的舱段构型及飞行姿态下，功率通道输出功率波动幅度由60%减小到7%，分体组合式双自由度对日定向系统构型能够适应空间站复杂的飞行工况。     

Elliptical vibration cutting of large-size thin-walled curved surface parts of pure iron by using diamond tool with active cutting edge shift

Large-size thin-walled curved surface parts of pure iron are crucial in aerospace, national defense, energy and precision physical experiments. However, the high machining accuracy and surface quality are difficult to achieve due to the serious tool wear and deformation when machining the parts with conventional cutting tools. In this paper, an elliptical vibration cutting (EVC) with active cutting edge shift (ACES) based on a long arbor vibration device is proposed for ultra-precision machining the pure iron parts by using diamond tool. Compared with cutting at a fixed cutting edge, the influence of ACES on the EVC was analyzed. Experiments in EVC of pure iron with ACES were conducted. The evolutions of the surface roughness, surface topography, and chip morphology with tool wear in EVC with ACES are revealed. The reasonable parameters of ultra-precision machining the pure iron parts by EVC with ACES were determined. It shows that the ACES has a slight influence on the machined surface roughness and surface topography. The diamond tool life can be significantly prolonged in EVC of pure iron with ACES than that with a fixed cutting edge, so that high profile accuracy and surface quality could be obtained even at higher nominal cutting speed. A typical thin-walled curved surface pure iron part with diameter ∅240 mm, height 122 mm, and wall thickness 2 mm was fabricated by the presented method, and its profile error and surface roughness achieved PV 2.2 μm and Ra less than 50 nm, respectively.     

恶劣天气下的仿生偏振定向方法

针对偏振光导航在恶劣天气下精度显著下降的问题,提出了一种可以在恶劣天气下基于大气偏振模式的定向算法。与现有方法相比,首次将三维块匹配与canny边缘检测结合的思想应用于修复被不同天气破坏的偏振角度图像中。具体而言,将偏振角度图像的修复分为噪声粗处理和边缘提取处理去噪两部分。在噪声粗处理阶段采用三维块匹配算法,在边缘提取处理去噪部分,利用canny边缘检测算法对偏振角度图像进行二次去噪。实验结果表明,该方法不仅能够提高晴朗天空下的定向精度,而且能够显著提升在阴天、沙尘、雾霾等恶劣天气条件下的导航定向精度,即使在偏振角图像对称∞模式被破坏的情况下,航向角精度仍可由9.4470°提高到1.6859°。     

恶劣天气下的仿生偏振定向方法

针对偏振光导航在恶劣天气下精度显著下降的问题，提出了一种可以在恶劣天气下基于大气偏振模式的定向算法。与现有方法相比，首次将三维块匹配与canny边缘检测结合的思想应用于修复被不同天气破坏的偏振角度图像中。具体而言，将偏振角度图像的修复分为噪声粗处理和边缘提取处理去噪两部分。在噪声粗处理阶段采用三维块匹配算法,在边缘提取处理去噪部分，利用canny边缘检测算法对偏振角度图像进行二次去噪。实验结果表明，该方法不仅能够提高晴朗天空下的定向精度，而且能够显著提升在阴天、沙尘、雾霾等恶劣天气条件下的导航定向精度，即使在偏振角图像对称∞模式被破坏的情况下，航向角精度仍可由9.4470°提高到1.6859°。     

Effects of fiber orientation on tool wear evolution and wear mechanism when cutting carbon fiber reinforced plastics

The aim of the present paper is to reveal the influence of different fiber orientations on the tool wear evolution and wear mechanism. Side-milling experiments with large-diameter milling tools are conducted. A finite element (FE) cutting model of carbon fiber reinforced plastics (CFRP) is established to get insight into the cutting stress status at different wear stages. The results show that different fiber orientations bring about distinct differences in the extent, profile and mechanism of tool wear. Severer wear occurs when cutting 45° and 90° plies, followed by 0°, correspondingly, the least wear is obtained when θ = 135° (θ represents the orientation of fibers). Moreover, the worn profiles of cutting tools when θ = 0° and 45° are waterfall edge, while round edge occurs when θ = 135° and a combined shape of waterfall and round edge is obtained when θ = 90°. The wear mechanisms under different fiber orientations are strongly dependent on the cutting stress distributions. The evolution of tool wear profile is basically consistent with the stress distribution on the tool surface at different wear stages, and the extent of tool wear is determined by the magnitude of stress on the tool surface. Besides, the worn edges produce an actual negative clearance angle, which decreases the actual cutting thickness and leads to compressing and bending failure of fibers beneath the cutting region as well as low surface qualities.