基于FANUC 0i系统的数控铣床的坐标旋转指令的使用研究

对教材上的坐标旋转指令(G68)应用例题的程序进行仿真加工,结果发现与图纸要求的形状不相符,分析其原因是该指令没有坐标原点平移的功能。要正确使用该指令实现加工,可以先采用坐标原点平移,再旋转的方法;或采用先控制刀具运动到旋转中心,再执行旋转指令,旋转指令后的程序段都采用增量值编程的方法。对这两种方法进行编程和仿真加工,结果显示符合图纸要求。     

陀螺接线柱加工工艺方法研究

以陀螺接线柱的加工为研究对象,通过分析现有加工中的难点、问题和加工工艺流程,重点研究了车加工问题机理和表面处理后出现空腔问题的机理,分析出接线柱组件合格率偏低的主要原因。并在此基础上,提出优化的加工工艺方法,以此降低陀螺接线柱的缺陷率。     

双轴精密离心机反转台精密姿态调节机构的设计与分析

双轴精密离心机是惯性导航设备进行精密标定的重要设备,它能够为惯性导航设备提供“0”加速度梯度的离心场。针对双轴精密离心机转台的精密姿态调节机构进行了设计与分析,利用两套同直径的配合球面作为球运动副,并作为主要承受离心场方向和重力场方向作用力的受力部件。利用带有万向节的精密螺杆作为角度姿态精密调节的机构,实现反转台铅垂度姿态的精密调节。经过精度分析,采用细牙螺纹螺杆,可实现反转台所需的铅垂度精度,即±10′。经过受力分析,精密螺杆受力状况良好,最大变形为0.47μm,最大应力为1.1561MPa,球运动副最大变形为6.24μm,最大应力为50.73MPa。因此,所设计的姿态调节机构满足其在双轴精密离心机中的应用。     

Surface-improvement mechanism of hybrid electrochemical discharge process using variable-amplitude pulses

Superalloys are commonly used in aircraft manufacturing; however, the requirements for high surface quality and machining accuracy make them difficult to machine. In this study, a hybrid electrochemical discharge process using variable-amplitude pulses is proposed to achieve this target. In this method, electrochemical machining (ECM) and electrical discharge machining (EDM) are unified into a single process using a sequence of variable-amplitude pulses such that the machining process realizes both good surface finish and high machining accuracy. Furthermore, the machining mechanism of the hybrid electrochemical discharge process using variable-amplitude pulses is studied. The mechanism is investigated by observations of machining waveforms and machined surface. It is found that, with a high-frequency transformation between high- and low-voltage waveforms within a voltage cycle, the machining mechanism is frequently transformed from EDM to pure ECM. The critical discharge voltage is 40 V. When pulse voltages greater than 40 V are applied, the machining accuracy is good; however, the surface has defects such as numerous discharge craters. High machining accuracy is maintained when high-voltage pulses are replaced by low-voltage pulses to enhance electrochemical dissolution. The results indicate that the proposed hybrid electrochemical discharge process using variable-amplitude pulses can yield high-quality surfaces with high machining accuracy.     

超细长空心活塞杆高速车削加工

介绍了长径比接近80∶1的超细长空心杆(活塞杆)的结构特点和加工难点。从理论联系实际的角度出发,分析了细长空心杆车削过程中容易出现的各种缺陷的产生原因,并提出针对性的措施以及提高生产效率的途径。     

环火星测量数据处理及精密轨道确定

为支持我国首次火星探测任务取得圆满成功,宇航动力学国家重点实验室将全自主开发的精密定轨平台系统,应用于环火星轨道确定中。为满足多对象、多弧段、多中心天体的定轨需求,平台系统设计了卫星结构、测站结构、观测结构和天体结构4大基础结构,并在4大基础结构之上,设计了灵活的弧段结构和估计结构。为验证平台系统是否具备环火星定轨能力,平台系统首先使用2020年上半年跟踪火星快车实验的数据对测量模型进行了检核,得到了理论测距和实测测距偏差（11m~21m）;其次,使用2009年实测双程测速和三程测速数据定轨,单独使用双程测速定轨,轨道与欧空局精密星历位置偏差最大不超过100m,测速残差的均方根（Root Mean Square, RMS）为0.0137(cm/s)。使用三程测速定轨,位置偏差不超过250m,三程测速RMS为0.0119（cm/s）;最后,使用两天三站测距仿真进行了自定轨验证,初轨和随机差都基本收敛回仿真初值。结果显示,宇航动力学国家重点实验室精密定轨系统能够满足我国首次火星探测任务的基本需求。     

刀具螺旋角对高速铣削系统稳定性的影响

考虑铣刀螺旋角的影响,将刀齿的切削过程划分为连续,切入和切出3个过程,建立了高速铣削系统的动力学模型。运用半离散估计技术,将无限维特征值稳定性判定问题转化为有限维Floquet变换矩阵特征乘子稳定性判定问题,判定了系统的稳定性,获得了系统的稳定性极限图。结果显示,在考虑刀具螺旋角影响的情况下,铣削系统稳定性极限较传统情况有所增大,出现了类似“岛”的结构,其位置由轴向切削深度和螺旋齿距的关系决定,且由于切削刀齿切入、切出过程的影响,“岛”不是孤立的,而是有稳定性“桥”连接。理论结果通过铣削实验进行了验证。     

复合工作液提高高速走丝电火花线切割效率研究

从极间放电特性的角度,分析了目前阻碍高速走丝电火花线切割(WEDM-HS)工艺指标提高的原因.指出WEDM-HS在使用含油比例较少的复合工作液作工作介质后,会因为极间冷却状态的改善而获得切割工艺指标的大幅度提高,一次稳定切割的效率已经超过200 mm2/min.     

Improving performance of macro electrolyte jet machining of TC4 titanium alloy: Experimental and numerical studies

Electrolyte jet machining (EJM) is a promising method for shaping titanium alloys due to its lack of tool wear, thermal and residual stress, and cracks and burrs. Recently, macro-EJM has attracted increasing attention for its high efficiency in machining wide grooves or planes. However, macro-EJM generates large amounts of electrolytic products, thereby increasing the difficulty of rapid product removal with a standard tool and reducing the surface quality. Therefore, for enhanced product transport, a novel tool with a back inclined end face was proposed for macro-EJM of TC4 titanium alloy. For comparison, also proposed were ones with a standard flat end face, a front inclined end face, and both front and back inclined end faces. The flow field distributions of all proposed tools were simulated numerically, and experiments were also conducted to validate the simulation results. The results show that one with a 5° back inclined end face can decrease the low-velocity flow zone in the machining area and increase the high-velocity flow zone at the back end of tool, thereby promoting rapid product removal. A relatively smooth bright-white groove surface was obtained. The same tool also resulted in the highest machining depth and material removal rate among the tested ones. In addition, rapid product removal was beneficial to the subsequent processing. Because of its rapid product removal, the machining depth and material removal rate during deep groove machining using the tool with a 5° back inclined end face were respectively 7% and 14% higher than those produced using a standard one. Moreover, the lowest bottom height difference of 0.027 mm can be obtained when the step-over value was 8.2 mm, and a plane with a depth of 0.285 mm and a bottom height difference of 0.03 mm was fabricated using the tool with a 5° back inclined end face.     

Influence mechanism of machining angles on force induced error and their selection in five axis bullnose end milling

In the machining of complicated surfaces, the cutters with large length/diameter ratios are used widely and the deformation of the machining system is one of the principal error sources.During the process planning stage, the cutting direction angle, the cutter lead and tilt angles are usually optimized to minimize the force induced error. It may lead to a low machining efficiency for bullnose end mills, as the material removal rates are different largely for different machining angles.In this pa...