难加工材料薄壁零件的振动切削技术研究

【作者】 罗跃；

【导师】 殷国富； 张明君；

【作者基本信息】 四川大学 ， 机械工程， 2004， 硕士

【摘要】 在切削加工领域，提高加工精度方法很多，其中一个非常重要的研究方向在于努力减小切削过程中的切削力和切削热。超声振动切削技术在降低切削力和切削热方面有重要的作用，可以较好地解决难加工材料、难加工零件以及精密加工等方面的一些工艺问题。为了推广应用这项新技术和解决特种武器系统中精密薄壁零件的加工难题，本文在中国工程物理研究院机械制造工艺研究所基金项目的资助下，进行难加工材料薄壁零件的振动切削技术研究的研究工作，主要研究成果和特点是： (1)对振动切削机理进行了较全面的分析和研究：首先对普通切削与振动切削进行了对比分析；其次对振动切削过程中的特点；切削刃的运动机理；振动切削时工件的动态变化；不敏感性振动切削机理；超声振动切削特点及原因分析；超声振切时切削液的润滑与冷却作用机理进行了分析。 (2)对超声振动切削国内外研究状况的分析，选择精车不锈钢薄壁圆筒外圆这道工序进行超声改造，利用超声振动车削技术来解决中国工程物理研究院机械制造工艺研究所的薄壁圆筒加工技术难题。 (3)通过对车间不锈钢薄壁圆筒的加工工艺的分析，对原有设备进行了超声改造。设计出了一套新型实用的超声车削加工设备，主要包括选用超声波发生器和换能器，设计变幅杆、超声车刀以及其他一些必要的零部件，尽量使系统结构简单；提出了一种新的结构和方法，设计出了一套超声车刀刀尖微调机构，使刀尖高度调整方便且能符合实际生产要求和习惯，调整方便。 (4)应用开发的系统和工艺进行了切削实验，解决实验调试过程中出现的问题，同时进行实验数据和现象的分析，通过对得到的实验数据进行回归分析，找出了优化的超四川大学硕士学位论文声加工切削参数，完成了研制报告。最后的实验结果表明采用超声加工方法车削薄壁件确实能够大幅度地提高零件的圆度和光洁度，提高刀具寿命。关键词:超声车削，薄壁件，刀尖微调机构，切削力，圆度，粗糙度更多还原

【Abstract】 There are many methods to improve machining precision. One of the most important research is to reduce cutting forces and the amount of heat produced during machining. The ultrasonic vibration cutting technology takes important roles in the reducing of cutting forces and heat. It has been used to solve many cutting difficulties encountered in ordinary machinery Manufacturing practices, especially in the cutting of some special materials and precision machining parts. In order to apply this new technology to solve the difficulties in the machining practices, with the help of other partners, we first use it in the Institute of Machining Technology of CAEP. The ultrasonic vibration cutting technology has been used in the turning of a stainless thin cylinder surface. This technology has also been used in other manufacturing practices in CAEP. The main results of this project include:(1)First of all, we analyze the mechanism of ultrasonic vibration cutting, introduce the research actuality of vibration cutting, discuss the mechanism of lubrication and the mechanism of cooling for lubricant.(2)After analyzing the current technologies used in the cutting of thin cylinder surface, a set of new ultrasonic vibration cutting tools are designed for the common cutting machining, including solid horn, ultrasonic vibration cutting tool and other parts.(3) With a lot of cutting experiments, the system are turn to theaccepted conditions. After analyzing the experimental data and results, the optimization turning parameters has been found, and a regress equation to represent their relationships is also obtained. In the design and cutting experiments, some new structures and methods are used, one of the example is the ultrasonic vibration cutting tools-tip height adjustment mechanism, which enables turning the positions of tools. Some key factors are also found. The experimental results show that the ultrasonic vibration cutting technology could improve the turning precision and roughness of thin cylinder surface greatly.更多还原