硼化锆整流罩加工工艺优化研究

发布时间：2018-10-22 15:51

【摘要】：硼化锆材料因具备优越性能被应用于制造超高速飞行器的鼻锥。由于其较高的脆硬性不可避免的成为难加工的对象，同时，整流罩的形状不规则导致其不能通过加工效率高的车床来完成，所以加工硼化锆整流罩十分困难。传统的加工方法完全依赖于加工中心磨削来完成整流罩的加工，通过效率低的磨削加工去除绝大多数的加工余量，此方法虽然能够保证加工精度，但是其加工成本太高，效率太低，一方面消耗大量的磨头，另一方面需要太多的加工时间。此方法难以实现较大批量的加工。所以，为了提高加工效率、降低加工成本，首先要从工艺上进行改进，然后进行工艺优化。本论文首先对硼化锆整流罩的加工流程进行整体研究，通过丰富的经验以及大量的实验总结出一套完整的加工工艺，解决了电火花线切割加工中电极丝易断的问题；使用UG6.0软件完成线切割切除整流罩曲面余量的路径设计；在线切割加工过程中，使用模糊理论对线切割电参数进行优化，得出脉冲幅值、脉间、主频、电流的最佳组合；在磨削过程中，采用正交试验极差分析法优化磨削参数，最终得到一组能够降低磨头使用数量，同时保证高效率的参数组合，即主轴转速、进给速度、吃刀量和磨头目数的最优组合。最后，通过对各加工步骤的总结，得出针对硼化锆整流罩的整套高质量的、具有一定指导意义的工艺理论。该工艺理论，，首先在整体高度上大大的优于传统加工方法，其次，局部加工中的工艺参数优化，有效地提高加工效率、降低了加工成本。最终，较传统方法硼化锆整流罩的加工时间减少60％多，磨具损耗减少80％。
[Abstract]:Zirconium boride materials have been used in the manufacture of nasal cones for super-high-speed aircraft due to their superior properties. Because of its high brittleness, it is inevitable that it is difficult to be machined, at the same time, the irregular shape of the fairing can not be finished by the lathe with high machining efficiency, so it is very difficult to process the zirconium boride fairing. The traditional machining method completely depends on the grinding of machining center to finish the fairing machining. Most of the machining allowance is removed by low efficiency grinding. Although this method can guarantee the machining accuracy, the processing cost is too high. Efficiency is too low, on the one hand consumption of a large number of grinding, on the other hand, too much processing time. This method is difficult to achieve large batch processing. Therefore, in order to improve the processing efficiency and reduce the processing cost, we should first improve the process and then optimize the process. In this paper, the machining process of zirconium boride fairing is studied as a whole. Through abundant experience and lots of experiments, a set of complete processing technology is summed up, which solves the problem that electrode wire breaks easily in WEDM. In the process of wire cutting, the fuzzy theory is used to optimize the electrical parameters of wire cutting, and the optimal combination of pulse amplitude, pulse, main frequency and current is obtained. In the grinding process, the orthogonal test range analysis method is used to optimize the grinding parameters. Finally, a group of parameters that can reduce the number of grinding heads and ensure high efficiency are obtained, that is, spindle speed, feed speed, and so on. The optimal combination of the amount of knife eaten and the number of grinding heads. Finally, through the summary of various processing steps, a complete set of high quality and instructive technology theory for zirconium boride fairing is obtained. Firstly, the technology theory is superior to the traditional processing method in the whole height. Secondly, the optimization of the process parameters in the local machining can effectively improve the processing efficiency and reduce the processing cost. In the end, the processing time of zirconium boride fairing is reduced by more than 60%, and the wear of abrasives is reduced by 80%.
【学位授予单位】：哈尔滨理工大学
【学位级别】：硕士
【学位授予年份】：2012
【分类号】：V262.3;TH162

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