大型自由曲面光学器件的超精密抛光方法

旨在提高大尺寸自由曲面光学器件精密抛光技术的精度与效率.通过构建一个机器人抛光中心作为抛光平台,并在包括单位圆域、单位正方形域及自由边界域在内的平面映射域内求解旅行商问题,通过投影计算圆形度数值,进行映射区域的分类,并将所获得的平面轨迹映射到曲面上获得用于大尺寸自由度超精密光学器件的抛光路径.本文算法综合考虑到计算效率...     

先进材料与工艺在机载导弹上的研究与应用

先进材料和工艺在机载导弹中的应用是实现机载导弹优异性能的基础和前提.主要讨论了用于机载导弹的复合材料、高温钛合金、铝锂合金、金属间化合物等先进材料和近无余量成形、超精密加工等先进工艺的特点以及国内外的发展概况.     

精密导电滑环表面微槽车削性能

采用超精密车削精密导电滑环导电环的方法,保证了精密导电滑环绝缘环与导电环的同轴度、环间距,使绝缘微槽变形量低于0.10 mm。建立了精密导电滑环的切槽模型,利用仿真分析讨论了主轴转速、进给速率、刀具前角和切削深度对微槽变形量的影响,并对模型进行了试验验证。结果表明:滑环微槽侧面变形量随主轴转速的增大而变大,当转速达到700 r/min时,变形量达到了0.10 mm,超出了滑环的精度要求;滑环微槽变形量随机床进给速率的增大而变大,当进给速率达到1.5 mm/min时,变形量超出了滑环的精度要求;滑环微槽变形量随着前角的增大而减小;滑环微槽变形量随切削深度的增大而变大,切削深度低于0.2 mm时,滑环变形量微乎其微。     

基于LabVIEW的超精密磨床嵌入式监控系统

针对超精密磨削机床的监控需求,基于NI–sbRIO硬件平台开发了一套应用于超精密磨床状态监测和数据采集的嵌入式监控系统,使用FPGA对温度、振动、声发射等信息进行实时数据采集,并使用实时处理器对数据进行分析和处理,实现对机床的实时状态监测和数据存储。通过FPGA编程取代硬件数据采集卡,成本低,灵活性强。试验表明,该系统能够胜任超精密磨床的监控任务。     

Twistor-based synchronous sliding mode control of spacecraft attitude and position

A synchronous control of relative attitude and position is required in separated ultra-quiet spacecraft, such as drag-free, disturbance-free, and distributed spacecraft. Thus, a twistor-based synchronous sliding mode control is investigated in this paper to solve the control problem of relative attitude and position among separated spacecraft modules. The twistor-based control design and the stability proof are implemented using the Modified Rodrigues Parameter (MRP). To evaluate the effectiveness of the proposed control method, this paper presents a case study of separated spacecraft flying control considering the mass uncertainty and external disturbances. In addition, a simulation study of the Proportional-Derivative (PD) control is also presented for comparison. The results indicate that the twistor-based sliding mode controller can ensure global asymptotic stability. The states converge fast with ultra-precision and ultra-stability in both the attitude and position. Moreover, the proposed twistor-based sliding mode control system is robust to the mass uncertainty and external disturbances.     

Anhydrous based shear-thickening polishing of KDP crystal

Based on the special physical–chemical characteristics of optical crystal in the field of aeronautics, a new anhydrous based shear-thickening polishing (ASTP) method has been proposed to restrain deliquescence and to improve physical properties for KDP machining. The ultra-precision polishing of KDP crystal is completed by ASTP. A kind of anhydrous based thickening polishing slurry (ATPS) was proposed in our work, and high-performance rheological properties were determined to achieve the ASTP of KDP crystal. A material removal model of ASTP in KDP machining is established, followed by the verification experiment of the prediction model. The maximum error of the predictive model is only 9.8%, which proves the validity of the material removal model for KDP polishing. The polishing experiments were carried out on the polishing platform developed by ourselves. The results show that the new polishing method can polish 20 mm × 20 mm × 5 mm KDP crystal and obtain a super-smooth surface with a surface roughness of 1.37 nm and high shape accuracy. The surface accuracy of polished KDP crystal reaches up to 0.68λ (RMS). The experimental results show that the ASTP is a potential ultra-precision machining method for KDP crystal.     

光学非球面超精密磨削质量控制技术研究

对光学非球面超精密磨削技术和表面加工质量控制技术进行了理论分析和实验研究。通过对MSG-325金刚石超精密车床的技术改造，可以对各种光学表面进行超精密磨削加工，尤其适合于光学非球面的超精密加工，在较短时间直接达到光学零件的表面质量要求。采用改造的磨削系统，加工出左端为抛物面，右端为双曲面的微晶玻璃内非球面，加工表面粗糙度Ra3nm。     

Interference and grinding characteristics in ultra-precision grinding of thin-walled complex structural component using a ball-end grinding wheel

As for ultra-precision grinding of difficult-to-process thin-walled complex components with ball-end grinding wheels, interference is easy to occur. According to screw theory and grinding kinematics, a mathematical model is established to investigate the interference and grinding characteristics of the ball-end wheel. The relationship between grinding wheel inclination angle, C axis rotation angle, grinding position angle and grinding wheel wear are analyzed. As the grinding wheel inclination angle increases, the C axis rotatable range decreases and the grinding position angle increases. The grinding position angle and wheel radius wear show a negative correlation with the C axis rotation angle. Therefore, a trajectory planning criteria for increasing grinding speed as much as possible under the premise of avoiding interference is proposed to design the grinding trajectory. Then grinding point distribution on the ball-end wheel is calculated, and the grinding characteristics, grinding speed and maximum undeformed chip thickness, are investigated. Finally, a complex structural component can be ground without interference, and surface roughness and profile accuracy are improved to 40.2 nm and 0.399 μm, compared with 556 nm and 3.427 μm before ultra-precision grinding. The mathematical model can provide theoretical guidance for the analysis of interference and grinding characteristics in complex components grinding to improve its grinding quality.     

Effect of grain refinement on cutting force of difficult-to-cut metals in ultra-precision machining

The nickel-based superalloy Inconel 718 is treated with Coupled Ultrasonic and Electric Pulse Treatment(CUEPT), and the surface grain is refined from the average size of 9550.0 nm to287.9, 216.3, 150.5, 126.3, 25.8 nm by different effective treatment currents, respectively. The ultraprecision turning experiments are carried out on the processed workpiece after CUEPT. The experimental results show that the average cutting force increases with the decrease of surface grain size.Moreover, a mathema...     

微结构表面超精密加工中切削条件的影响分析

介绍了微结构功能表面加工中的问题,以同轴调制锯齿波微结构的金刚石超精密加工为例阐述了其加工原理,结合试验对刀具刀尖圆弧半径、被加工材料和切削液等切削条件与金刚石超精密切削加工后的微结构功能表面之间的关系进行了分析与讨论,并对主轴转速和刀具进给速度等切削用量与金刚石超精密切削出的微结构功能表面之间的关系进行了分析与讨论.