航空增材制造复杂结构件表面光整加工技术研究及进展
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摘要
增材制造是解决航空复杂结构件制造难题的有效方法。首先概述了增材制造技术原理、特点及其在航空领域的应用,并深入评述了增材制造技术在材料力学性能、表面质量等方面面临的挑战,指出增减材复合制造的方法,并表明先进表面光整加工技术是提升航空增材制造复杂结构件表面质量和精度的有效途径。重点阐述了高加工可达性的磨粒流加工技术在航空复杂结构件精密抛光中的优势,并总结了保持零件精度同时改善表面质量需要重点研究的内容。
Additive manufacturing is an effective way to solve the manufacturing problems of aeronautical complex structural parts. Firstly, the principle and characteristics of additive manufacturing technology and its application in aeronautical field are introduced. Furthermore, the challenges faced by additive manufacturing technology in terms of material mechanical properties and surface quality are discussed deeply. Moreover, it is pointed out that additive and subtractive hybrid manufacturing and advanced finishing technology are effective approaches to the improvement in surface quality and accuracy of aeronautical complex structural parts. The advantages of abrasive flow machining with high processing accessibility in the precision polishing of aeronautical complex structural parts are highlighted, and important researches of maintaining the precision of parts while improving the surface quality are recommended.
Additive manufacturing is an effective way to solve the manufacturing problems of aeronautical complex structural parts. Firstly, the principle and characteristics of additive manufacturing technology and its application in aeronautical field are introduced. Furthermore, the challenges faced by additive manufacturing technology in terms of material mechanical properties and surface quality are discussed deeply. Moreover, it is pointed out that additive and subtractive hybrid manufacturing and advanced finishing technology are effective approaches to the improvement in surface quality and accuracy of aeronautical complex structural parts. The advantages of abrasive flow machining with high processing accessibility in the precision polishing of aeronautical complex structural parts are highlighted, and important researches of maintaining the precision of parts while improving the surface quality are recommended.
引文
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[20]GREITEMEIER D,PA L M F,SYASSEN F,et al.Fatigue performance of additive manufactured TiAl6V4 using electron and laser beam melting[J].International Journal of Fatigue,2017,94:211-217.
[21]RAHMATIS,VA ABLIE.Evaluation of analytical modeling for improvement of surface roughness of FDMtest part using measurement results[J].The International Journal of Advanced Manufacturing Technology,2015,79(5):823-829.
[22]GU D D,SHENY F.Balling phenomena in direct laser sintering of stainless steel powder:metallurgical mechanisms and control methods[J].Materials&Design,2009,30(8):2903-2910.
[23]MUMTAZ K,HOPKINSON N.Top surface and side roughness of Inconel 625parts processed using selective laser melting[J].Rapid Prototyping Journal,2009,15(2):96-103.
[24]KRUTH J P,LEVY G,KLOCKEF,et al.Consolidation phenomena in laser and powder-bed based layered manufacturing[J].CIRP Annals-Manufacturing Technology,2007,56(2):730-759.
[25]LIU B C,WILDMAN R,TUCKC,et al.Investigation the effect of particle size distribution on processing parameters optimisation in selective laser melting process[J/OL].[2019-03-02]http://sffsymposium.engr.utexas.edu/Manuscripts/2011/2011-18-Liu.pdf.
[26]FLY NN J M,SHOKRANIA,NEWMAN S T,et al.Hybrid additive and subtractive machine tools-research and industrial developments[J].International Journal of Machine Tools and Manufacture,2016,101:79-101.
[27]白倩,董志刚,闫英,等.金属增减材复合制造专业硕士实践教学平台建设[J].实验室科学,2018,21(2):158-160.BAI Qian,DONG Zhigang,YAN Ying,et al.Development of additive/subtractive hybrid manufacturing practical teaching platform for full-time master of engineering students[J].Laboratory Science,2018,21(2):158-160.
[28]BEAUCAMP A T,NAMBA Y,CHARLTON P,et al.Finishing of additively manufactured titanium alloy by shape adaptive grinding(SAG)[J].Surface Topography:Metrology and Properties,2015,3(2):024001.
[29]BHADURID,PENCHEV P,BATAL A,et al.Laser polishing of 3D printed mesoscale components[J].Applied Surface Science,2017,405:29-46.
[30]MARIMUTHUS,TRIANTAPHYLLOU A,ANTAR M,et al.Laser polishing of selective laser melted components[J].International Journal of Machine Tools and Manufacture,2015,95:97-104.
[31]LAMIKIZ A,SáNCHEZ J A,LóP EDELACALLE LN,et al.Laser polishing of parts built up by selective laser sintering[J].International Journal of Machine Tools and Manufacture,2007,47(12/13):2040-2050.
[32]?YCZKOWSKA E,SZYMCZYKP,DYBA?A B,et al.Chemical polishing of scaffolds made of Ti-6Al-7Nb alloy by additive manufacturing[J].Archives of Civil&Mechanical Engineering,2014,14(4):586-594.
[33]PYKA G,BURAKOWS KIA,KERCKHOFS G,et al.Surface modification of Ti6Al4V open porous structures produced by additive manufacturing[J].Advanced Engineering Materials,2012,14(6):363-370.
[34]高航,李世宠,付有志,等.金属增材制造格栅零件磨粒流抛光[J].航空学报.2017,38(10):231-239.GAO Hang,LI Shichong,FU Youzhi,et al.Abrasive flow machining of additively manufactured metal grilling parts[J].Acta Aeronautica et Astronautica Sinica,2017,38(10):231-239.
[35]PENG C,FU Y Z,WEI H B,et al.Study on improvement of surface roughness and induced residual stress for additively manufactured metal parts by abrasive flow machining[J].Procedia CIRP,2018,71:386-389.
[36]WILLIAMS R E,MELTON V L.Abrasive flow finishing of stereolithography prototypes[J].Rapid Prototyping Journal,1998,4(2):56-67.
[37]BERGMANN C,SCHMIEDELA,UHLMANN E.Postprocessing of selective laser melting components using abrasive flow machining and cleaning[C]//Proceedings of International Additive Maufacturing Symposium.Markness,2013.
[38]WANG A C,TSAI L,LIANG KZ,et al.Uniform surface polished method of complex holes in abrasive flow machining[J].Transactions of Nonferrous Metals Society of China,2009,19(S1):250-257.
[39]WANG A C,CHENG K C,CHENK Y,et al.A study of surface uniformity for helical passageways in abrasive flow machining[J].Przegl?d Elektrotechniczny,2012,88(9B):13-16.
[40]FU Y Z,WANG X P,GAO H,et al.Blade surface uniformity of blisk finished by abrasive flow machining[J].The International Journal of Advanced Manufacturing Technology,2016,84(5-8):1725-1735.
[41]高航,吴鸣宇,付有志,等.流体磨料光整加工理论与技术的发展[J].机械工程学报,2015,51(7):174-187.GAO Hang,WU Mingyu,FU Youzhi,et al.Development of theory and technology in fluid abrasive finishing technology[J].Journal of Mechanical Engineering,2015,51(7):174-187.
[2]FRAZIER W E.Metal additive manufacturing:a review[J].Journal of Materials Engineering and Performance,2014,23(6):1917-1928.
[3]曾凡昌.锻压先进制造技术及在航空工业领域的应用[J].航空制造技术,2009,52(6):26-29.ZENG Fanchang.Advanced forging manufacturing technology and its application in aviation industry[J].Aeronautical Manufacturing Technology,2009,52(6):26-29.
[4]王华明,张述泉,汤海波,等.大型钛合金结构激光快速成形技术研究进展[J].航空精密制造技术,2008,41(6):28-30.WANG Huaming,ZHANG Shuquan,TANG Haibo,et al.Research progress of laser rapid prototyping technology for large titanium alloy structures[J].Aviation Precision Manufacturing Technology,2008,41(6):28-30.
[5]田宗军,顾冬冬,沈理达,等.激光增材制造技术在航空航天领域的应用与发展[J].航空制造技术,2015,58(11):38-42.TIAN Zongjun,GU Dongdong,SHENLida,et al.Application and development of laser additive manufacturing technology in aeronautics and astronautics[J].Aeronautical Manufacturing Technology,2015,58(11):38-42.
[6]张小伟.金属增材制造技术在航空发动机领域的应用[J].航空动力学报,2016,31(1):10-16.ZHANG Xiaowei.Application of metal additive manufacturing in aero-engine[J].Journal of Aerospace Power,2016,31(1):10-16.
[7]ZHAO X M,LIN X,CHEN J,et al.The effect of hot isostatic pressing on crack healing,microstructure,mechanical properties of Rene88DT superalloy prepared by laser solid forming[J].Materials Science and Engineering:A,2009,504(1/2):129-134.
[8]SAMES W J,MEDINA F,PETERW H,et al.Effect of process control and powder quality on Inconel 718 produced using electron beam melting[C]//Proceedings of 8th International Symposium on Superalloy 718 and Derivatives.Hoboken:John Wiley&Sons,Inc.,2014.
[9]JOHNSON A S,SHUAIS,SHAMSAEI N,et al.Fatigue behavior and failure mechanisms of direct laser deposited Inconel 718[C]//Proceedings of the 27th Annual International Solid Freeform Fabrication Symposium-An Additive Manufacturing.Austin:Laboratory for Freeform Fabrication and University of Texas at Austin,2016.
[10]GU D D,HAGEDORN Y C,MEINERS W,et al.Densification behavior,microstructure evolution,and wear performance of selectivelas ermelting processed commercially pure titanium[J].Acta Materialia,2012,60(9):3849-3860.
[11]BARBAS A,BONNET A S,LIPINSKI P,et al.Development and mechanical characterization of porous titanium bone substitutes[J].Journal of the Mechanical Behavior of Biomedical Materials,2012,9(3):34-44.
[12]WEN S F,LIS,WEIQS,et al.Effect of molten pool boundaries on the mechanical properties of selective laser melting parts[J].Journal of Materials Processing Technology,2014,214(11):2660-2667.
[13]THIJS L,KEMPEN K,KRUTH J P,et al.Fine-structured aluminium products with controllable texture by selective laser melting of pre-alloyed AlSi10Mg powder[J].Acta Materialia,2013,61(5):1809-1819.
[14]ZHANG D Q,LIU Z H,CAI Q Z,et al.Influence of Ni content on microstructure of W-Ni alloy produced by selective laser melting[J].International Journal of Refractory Metals&Hard Materials,2014,45:15-22.
[15]ATTAR H,CALIN M,ZHANG LC,et al.Manufacture by selective laser melting and mechanical behavior of commercially pure titanium[J].Materials Science&Engineering A,2014,593(2):170-177.
[16]MONRO Y K,DELGADO J,CIURANA J.Study of the pore formation on CoCrMo alloys by selective laser melting manufacturing process[J].Procedia Engineering,2013,63:361-369.
[17]BAUEREI?A,SCHAROWSKY T,K?RNER C.Defect generation and propagation mechanism during additive manufacturing by selective beam melting[J].Journal of Materials Processing Technology,2014,214(11):2522-2528.
[18]ABOULKHAIR N T,EVERITTN M,ASHCROFT I,et al.Reducing porosity in AlSi10Mg parts processed by selective laser melting[J].Additive Manufacturing,2014,1-4:77-86.
[19]MASKERY I,ABOULKHAIRN T,TUCK C,et al.Fatigue performance enhancement of selectively laser melteda uminiumalloy by heattreatment[C]//Proceedings of 26th Annual International Solid Freeform Fabrication Symposium-An Additive Manufacturing.Austin,2015.
[20]GREITEMEIER D,PA L M F,SYASSEN F,et al.Fatigue performance of additive manufactured TiAl6V4 using electron and laser beam melting[J].International Journal of Fatigue,2017,94:211-217.
[21]RAHMATIS,VA ABLIE.Evaluation of analytical modeling for improvement of surface roughness of FDMtest part using measurement results[J].The International Journal of Advanced Manufacturing Technology,2015,79(5):823-829.
[22]GU D D,SHENY F.Balling phenomena in direct laser sintering of stainless steel powder:metallurgical mechanisms and control methods[J].Materials&Design,2009,30(8):2903-2910.
[23]MUMTAZ K,HOPKINSON N.Top surface and side roughness of Inconel 625parts processed using selective laser melting[J].Rapid Prototyping Journal,2009,15(2):96-103.
[24]KRUTH J P,LEVY G,KLOCKEF,et al.Consolidation phenomena in laser and powder-bed based layered manufacturing[J].CIRP Annals-Manufacturing Technology,2007,56(2):730-759.
[25]LIU B C,WILDMAN R,TUCKC,et al.Investigation the effect of particle size distribution on processing parameters optimisation in selective laser melting process[J/OL].[2019-03-02]http://sffsymposium.engr.utexas.edu/Manuscripts/2011/2011-18-Liu.pdf.
[26]FLY NN J M,SHOKRANIA,NEWMAN S T,et al.Hybrid additive and subtractive machine tools-research and industrial developments[J].International Journal of Machine Tools and Manufacture,2016,101:79-101.
[27]白倩,董志刚,闫英,等.金属增减材复合制造专业硕士实践教学平台建设[J].实验室科学,2018,21(2):158-160.BAI Qian,DONG Zhigang,YAN Ying,et al.Development of additive/subtractive hybrid manufacturing practical teaching platform for full-time master of engineering students[J].Laboratory Science,2018,21(2):158-160.
[28]BEAUCAMP A T,NAMBA Y,CHARLTON P,et al.Finishing of additively manufactured titanium alloy by shape adaptive grinding(SAG)[J].Surface Topography:Metrology and Properties,2015,3(2):024001.
[29]BHADURID,PENCHEV P,BATAL A,et al.Laser polishing of 3D printed mesoscale components[J].Applied Surface Science,2017,405:29-46.
[30]MARIMUTHUS,TRIANTAPHYLLOU A,ANTAR M,et al.Laser polishing of selective laser melted components[J].International Journal of Machine Tools and Manufacture,2015,95:97-104.
[31]LAMIKIZ A,SáNCHEZ J A,LóP EDELACALLE LN,et al.Laser polishing of parts built up by selective laser sintering[J].International Journal of Machine Tools and Manufacture,2007,47(12/13):2040-2050.
[32]?YCZKOWSKA E,SZYMCZYKP,DYBA?A B,et al.Chemical polishing of scaffolds made of Ti-6Al-7Nb alloy by additive manufacturing[J].Archives of Civil&Mechanical Engineering,2014,14(4):586-594.
[33]PYKA G,BURAKOWS KIA,KERCKHOFS G,et al.Surface modification of Ti6Al4V open porous structures produced by additive manufacturing[J].Advanced Engineering Materials,2012,14(6):363-370.
[34]高航,李世宠,付有志,等.金属增材制造格栅零件磨粒流抛光[J].航空学报.2017,38(10):231-239.GAO Hang,LI Shichong,FU Youzhi,et al.Abrasive flow machining of additively manufactured metal grilling parts[J].Acta Aeronautica et Astronautica Sinica,2017,38(10):231-239.
[35]PENG C,FU Y Z,WEI H B,et al.Study on improvement of surface roughness and induced residual stress for additively manufactured metal parts by abrasive flow machining[J].Procedia CIRP,2018,71:386-389.
[36]WILLIAMS R E,MELTON V L.Abrasive flow finishing of stereolithography prototypes[J].Rapid Prototyping Journal,1998,4(2):56-67.
[37]BERGMANN C,SCHMIEDELA,UHLMANN E.Postprocessing of selective laser melting components using abrasive flow machining and cleaning[C]//Proceedings of International Additive Maufacturing Symposium.Markness,2013.
[38]WANG A C,TSAI L,LIANG KZ,et al.Uniform surface polished method of complex holes in abrasive flow machining[J].Transactions of Nonferrous Metals Society of China,2009,19(S1):250-257.
[39]WANG A C,CHENG K C,CHENK Y,et al.A study of surface uniformity for helical passageways in abrasive flow machining[J].Przegl?d Elektrotechniczny,2012,88(9B):13-16.
[40]FU Y Z,WANG X P,GAO H,et al.Blade surface uniformity of blisk finished by abrasive flow machining[J].The International Journal of Advanced Manufacturing Technology,2016,84(5-8):1725-1735.
[41]高航,吴鸣宇,付有志,等.流体磨料光整加工理论与技术的发展[J].机械工程学报,2015,51(7):174-187.GAO Hang,WU Mingyu,FU Youzhi,et al.Development of theory and technology in fluid abrasive finishing technology[J].Journal of Mechanical Engineering,2015,51(7):174-187.