整体构件异形通道精密电火花加工工程应用研究

发布时间：2018-04-27 20:15

本文选题：异形通道 + 电火花加工　；参考：《南京航空航天大学》2017年硕士论文

【摘要】：含异形通道结构的整体构件因其具有轻量化、高寿命、高可靠性等优点,在先进航空航天及武器装备发动机、大型船舶、汽车等设计中被越来越广泛地采用。然而由于异形通道几何结构复杂且材料难切削,增大了其整体制造难度。数控电火花加工技术具有不受材料力学性能限制、加工精度高、柔性好等优点,特别适合于整体构件异形通道的加工。为优质、高效地发挥电火花加工整体构件异形通道的优势,本文以典型整体构件异形通道为研究对象,开展精密电火花加工工程应用研究,主要研究内容如下:1.通过分析典型整体构件异形通道结构的主要特点和加工难点,结合电火花加工工艺特点,制定异形通道结构电火花加工工艺方案。2.针对工艺方案中大刚度电极设计和运动轨迹优化设计的难点,提出一种电极设计方法,保证电极成形面的完整和电极刚度的最大化;结合两种不同的目标函数对运动轨迹进行优化,确定各轨迹在粗、精加工中的适用范围,提高加工效率和加工精度。3.在加工仿真的基础上,对加工仿真结果进行误差分析,判断设计的电极及运动轨迹是否满足加工精度要求;采用数据点比较法,结合UG二次开发平台,开发出误差分析模块,实现成形电极和异形通道的高效、高精度误差分析。以典型整体构件异形通道为例进行电火花试制加工,加工完成的通道达到了较高精度,满足了设计要求的精度,从而论证了整个工艺方案的可行性;总结出影响整体构件异形通道加工精度的主要因素,并提出了解决方案,对解决整体构件异形通道的制造难题具有重要意义。
[Abstract]:Because of its advantages of light weight, high life and high reliability, the whole structure with special-shaped channel structure is more and more widely used in the design of advanced aeronautics, aerospace and weapon equipments, large ships, automobiles and so on. However, due to the complex geometric structure of the special-shaped channel and the difficult cutting of the material, it is more difficult to manufacture the special-shaped channel. The NC EDM technology has the advantages of not limited mechanical properties of materials, high machining precision and good flexibility, etc. It is especially suitable for the machining of irregular channels of integral components. In order to give full play to the advantages of the special channel of EDM, this paper takes the typical monolithic component special-shaped channel as the research object, and carries out the research on the application of precision EDM, the main research contents are as follows: 1. Based on the analysis of the main characteristics and machining difficulties of the typical monolithic structural special-shaped channel structure, combined with the characteristics of EDM technology, the EDM process scheme of special-shaped channel structure was established. In view of the difficulties in the design of large stiffness electrode and the optimum design of motion trajectory, a method of electrode design is proposed to ensure the integrity of the electrode forming surface and the maximization of the electrode stiffness. Combined with two different objective functions, the motion trajectory is optimized to determine the applicable range of each trajectory in rough and finishing machining, and to improve the machining efficiency and machining precision. 3. On the basis of machining simulation, the error analysis of machining simulation results is carried out to judge whether the designed electrode and motion track meet the requirements of machining accuracy, and the error analysis module is developed by using the method of data point comparison and combining with the secondary development platform of UG. The high-efficiency and high-precision error analysis of shaped electrodes and special-shaped channels is realized. Taking the typical integral component special-shaped channel as an example, the EDM trial machining is carried out, and the completed channel reaches a higher precision, which meets the precision of the design requirements, and thus demonstrates the feasibility of the whole process plan. The main factors affecting the machining accuracy of the monolithic special-shaped channel are summarized, and the solution is put forward, which is of great significance to solve the manufacturing problem of the monolithic component special-shaped channel.
【学位授予单位】：南京航空航天大学
【学位级别】：硕士
【学位授予年份】：2017
【分类号】：TG661

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