难加工材料小孔振动攻丝的试验研究
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摘要
与传统的攻丝方式相比,振动攻丝是一种较新的复合加工方法,它可以提高工艺系统刚度,有效地降低攻丝扭矩,提高螺纹加工质量,特别是可以解决钛合金、高温合金等难加工材料小孔攻丝的难题。故研究难加工材料的振动攻丝具有重要的现实意义。
首先,对丝锥进行运动学分析表明:振动攻丝可以提高丝锥的等效扭转刚度,振动攻丝的重复切削特性可以降低摩擦扭矩;通过弹性力学及断裂力学分析表明:脉冲力切削使应力强度因子发生剧烈变化,微裂纹的产生与扩展导致攻丝扭矩的降低;振动攻丝的脉冲切削,有利于切削液进入切削区,降低摩擦扭矩。
然后,采用原振动攻丝机对高温合金GH4169和钛合金TC4两种难加工材料进行了攻丝试验。单因素法试验以振动频率f、振幅A及净切削时间比nc为参数,研究各个参数对振动攻丝扭矩的影响规律;正交设计试验法是根据正交表进行试验,进而采用回归方程求解振动攻丝扭矩的经验公式。并且采用不同切削液进行了振动攻丝试验,研究了切削液的效果。
最后,针对原攻丝机控制系统的不足,对控制系统的硬件部分、PCB板及控制面板进行了设计,并用模块化思想编写了程序。
振动攻丝的试验结果表明:在试验条件下,攻丝扭矩随频率的提高而降低,随净切削时间比的增加而增大,且净切削时间比对攻丝扭矩的影响均为最显著,振幅对攻丝扭矩的影响呈非线性;振动攻丝所得的螺纹的牙形完整,形状规则;切削液的使用可以降低振动攻丝扭矩。故振动攻丝可以有效地解决难加工材料小孔攻丝的工艺难题。
Compared with the traditional method of tapping, vibration tapping is a new method of compound manufacturing. It has the advantages of enhancing the torsional rigidity of manufacture system, a much lower tapping torque, much better quality of screw thread. Vibration tapping is then proved to be a practical solution to the problem of small-hole tapping in difficult-to-cut materials. Now researching on the mechanism of vibration tapping and designing a much better system has a great practical significance.
Through analyses of moving, the vibration tapping can enhance the torsional rigidity of manufacture system, and having a much lower friction torque. Through analyses of elasticity and plastic, it proofs that the impulse cutting can crack the metal, the crack will result in fall of tapping torque. The impulse cutting also let the lube be easy to get in the section of cutting, it help to low the friction torque.
By using simple-factor experiment and Orthogonal Experiment the author have done a great deal experiment with GH4169 and TC4. In simple-factor experiment, the author used amplitudes, frequency, net cutting time ratio as the parameters, to get the regular pattern of tapping torque as parameter changing. Through Orthogonal Experiment, the author have gained the experience formula. By using different lube to do experiment, the author research on the effect of lube.
Lastly, contra-posing with the disadvantage of former system, designed a new system and finished the control program by using the idea of modularization.
Through the experiment of vibration tapping, we find the tapping torque augmenting as the frequency diminishing, augmenting as net cutting time ratio augmenting, and it is most influenced by net cutting time ratio. Use of lube is effective to low friction torque. Morphology of teeth of vibration tapping is integrated. All these proof that vibration tapping is a effective method to resolve small hole tapping in difficult-to-cut materials.
首先,对丝锥进行运动学分析表明:振动攻丝可以提高丝锥的等效扭转刚度,振动攻丝的重复切削特性可以降低摩擦扭矩;通过弹性力学及断裂力学分析表明:脉冲力切削使应力强度因子发生剧烈变化,微裂纹的产生与扩展导致攻丝扭矩的降低;振动攻丝的脉冲切削,有利于切削液进入切削区,降低摩擦扭矩。
然后,采用原振动攻丝机对高温合金GH4169和钛合金TC4两种难加工材料进行了攻丝试验。单因素法试验以振动频率f、振幅A及净切削时间比nc为参数,研究各个参数对振动攻丝扭矩的影响规律;正交设计试验法是根据正交表进行试验,进而采用回归方程求解振动攻丝扭矩的经验公式。并且采用不同切削液进行了振动攻丝试验,研究了切削液的效果。
最后,针对原攻丝机控制系统的不足,对控制系统的硬件部分、PCB板及控制面板进行了设计,并用模块化思想编写了程序。
振动攻丝的试验结果表明:在试验条件下,攻丝扭矩随频率的提高而降低,随净切削时间比的增加而增大,且净切削时间比对攻丝扭矩的影响均为最显著,振幅对攻丝扭矩的影响呈非线性;振动攻丝所得的螺纹的牙形完整,形状规则;切削液的使用可以降低振动攻丝扭矩。故振动攻丝可以有效地解决难加工材料小孔攻丝的工艺难题。
Compared with the traditional method of tapping, vibration tapping is a new method of compound manufacturing. It has the advantages of enhancing the torsional rigidity of manufacture system, a much lower tapping torque, much better quality of screw thread. Vibration tapping is then proved to be a practical solution to the problem of small-hole tapping in difficult-to-cut materials. Now researching on the mechanism of vibration tapping and designing a much better system has a great practical significance.
Through analyses of moving, the vibration tapping can enhance the torsional rigidity of manufacture system, and having a much lower friction torque. Through analyses of elasticity and plastic, it proofs that the impulse cutting can crack the metal, the crack will result in fall of tapping torque. The impulse cutting also let the lube be easy to get in the section of cutting, it help to low the friction torque.
By using simple-factor experiment and Orthogonal Experiment the author have done a great deal experiment with GH4169 and TC4. In simple-factor experiment, the author used amplitudes, frequency, net cutting time ratio as the parameters, to get the regular pattern of tapping torque as parameter changing. Through Orthogonal Experiment, the author have gained the experience formula. By using different lube to do experiment, the author research on the effect of lube.
Lastly, contra-posing with the disadvantage of former system, designed a new system and finished the control program by using the idea of modularization.
Through the experiment of vibration tapping, we find the tapping torque augmenting as the frequency diminishing, augmenting as net cutting time ratio augmenting, and it is most influenced by net cutting time ratio. Use of lube is effective to low friction torque. Morphology of teeth of vibration tapping is integrated. All these proof that vibration tapping is a effective method to resolve small hole tapping in difficult-to-cut materials.
引文
1 李企芳. 难加工材料的加工技术. 科学技术出版社, 1992:34~38
2 T. Saotome, F. Yokoi. Precision Internal Threading of Stainless Steel. Precision Engineering, 1984,6(2):73~78
3 A. Bolden. Tapping Troubles. The Hidden Cause. Cutting Tool, 1990,3:8~12
4 韩荣第, 王扬. 现代机械加工新技术. 电子工业出版社, 2003:67~72
5 李海林, 王贵成. 低频振动攻丝提高加工精度的试验研究. 工艺与工艺装备, 2002,11:47~50
6 郑建明, 肖继明, 李言. 振动攻丝切削力及加工精度的研究. 西安理工大学学报, 2002,16(4):339~342
7 张春哗, 李海林, 王贵成. 采用振动攻丝提高工艺系统刚度的机理研究. 工具技术, 2003,37(3):11~13
8 B. Zhang, F. Yang. Fundamental Aspects in Vibration-Assisted Tapping. J. of Materials Processing Technology. 2003,132 :345~352
9 黄玉新, 黄友荣. 低频扭振攻丝加工的研究. 机械设计与制造, 2001(3):86~87
10 李祥林, 薛万夫. 振动切削及其在机械加工中的应用. 北京科学技术出版社, 1985:260~265
11 隈部纯一郎. 精密加工振动切削(基础与应用). 韩一昆译. 机械工业出版社, 1985:1~17
12 S. S. Patil, S. Pande. Some Investigations on Vibratory Tapping Process. Int. J. Mach. Tools Manufact. 1987,27(3):343~350
13 G. Hyatt. Innovation in Holemaking. Tool&Production, 1995,5:35~39
14 苟琪. 振动攻丝动态切削力研究. 中国机械工程, 1998,9(4):15~17
15 韩荣第, 刘建, 韩滨. SiCw/Al 铝复合材料振动攻丝扭矩的试验研究. 哈尔滨工业大学学报, 2002,34(4):30~34
16 王立平, 杨叔子. 变参数振动钻削提高微小孔加工精度的研究. 工具技术, 1998, 32(11):3~16
17 佟宇, 吴慧英. 用微机控制振动攻丝. 机械工艺师,1993(10)
18 M. L. Liu. Development of Next Generation Controller within Modern Manufacturing. Northeastern University Press, 1994:33~37
19 姜 大 志 , 孙 俊 兰 . 低 频 振 动 攻 丝 装 置 的 研 究 和 应 用 . 工 艺 装 备 ,2000,10:43~44
20 A. Shepherd. Top-Speed Tapping. Cutting Tool, 1991,3:39~48
21 殷宝麟, 韩荣第. 振动切削机理研究. 机械研究与应用, 2004,17(10):41~43
22 S. Eaetal. Vibratory Drilling of Holes in Stainless and Heat Resisting. Steel. Russian Eng. J., 1962,42(1):56
23 D. Jeong, I. Choi. Micro Surface Phenomenon of Ductile Cutting in Ultrasonic Vibration Cutting of Optical Plastics. J. Materials Processing Technology, 1997, 68:89~98
24 李海林, 王贵成. 低频振动攻丝技术. 机械设计与制造, 2003(1):87~89
25 叶大鹏, 何聪慧. 螺孔振动攻丝实验方法及其运动关系分析. 福建农业大学学报, 1999,28(4):505~508
26 王艺, 王朴. 振动切削在攻丝加工中的应用. 林业机械与木工设备, 1999,27 (5):26~28
27 韩荣第. 难加工材料切削加工. 机械工业出版社, 1996:46~65
28 苟琪, 陈鼎昌. 钛合金振动攻丝的切削扭矩模型. 机械研究与应用, 1997,3:18~21
29 张德远, 陈志同. 钛合金振动攻丝降低攻丝扭矩的研究. 机械工程学报, 1994,30(2):18~23
30 E. A . Nilkitin. Ultrasound Speeds up Thread Tapping Jobs. Soviet Engineering Research. 1989,9(4):118~119
31 周泽华. 金属切削原理. 上海科学技术出版社, 1993:60~65
32 C. W. Shul, K. Y. Lee. Dynamic Response of Subsurface Interface Crack in Multi-layered Orthotropic Half-space under Anti-plane Shear Impact Loading. Int. J. Solids and Structure, 2001,38(7):3563~3574
33 H. Qiu, M. Enoki. Effect of Pre-strain on Fracture Toughens of Ductile Structural Steels under Static and Dynamic Loading. Engineering Fracture Mechanics, 2005,72:1624~1633
34 王贵成, 李海林, 王树林, 裴宏杰. 低频振动攻丝丝锥动态角位移的研究. 机械工程师, 2003,14(9):1593~1596
35 Z. Lin, S. Li. A Study of Deformation of the Machined Work-piece and Tool under Different Low Cutting Velocities with an Elastic Cutting Tool. Int. J. Sci. , 1998,40:663~681
36 M. Lucas, G. Graham. Enhanced Vibration Control of an Ultrasonic CuttingProcess. Ultrasonic, 1996,34:205~211
37 王敏中. 弹性力学引论. 北京大学出版社, 2001:83~88
38 李光军, 张德远. 难加工材料的低频振动攻丝研究. 机械工程师, 2004,15(3):494~497
39 G. Eugene. Tapping Goes High-tech. Tool&Production, 1991,5: 35~39
40 X. Zhao. The Stress-intensity Factor for a Half Plane Crack in a Transversely Isotropic Solid Due to Impact Point Loading on the Crack Faces. Int. Journal of Solids and Structures, 2001,38:2851~2865
41 Q. Gou, Z. T. Chen. Research on Machining Titanium Alloys Blind Fastener. Journal of Qingdao University, 1997(10):55~59
42 W. Zhang. Fundamentals Elasticity Mechanics and Finite Element Method. Proc. Int. Mech. Engrs, 2003:206~211
43 D. Y. Zhang, Z. T. Chen. Relif-face Friction in Vibration Tapping. Int. J. Mech. Sci. , 1998,40(12):1209~1222
44 L. Wang. Prediction and Compute Simulation of Dynamic Thrust and Torque in Vibration Drilling. Proc. Int. Mech. Engrs. , 1998,212: 489~497
45 L. Cronjager and D. Meister. Drilling of Fiber and Particle Reinfored Alumin-inm. Composites Material Technology, 1991(1):37~45
46 T. Cao, J. Sutherland. Investigation of Thread Tapping Load Characteristics through Mechanistic Modeling and Experimentation. Int. J. Machine Tools and Manufacture, 2002,42:1527~1538
47 赵建生. 断裂力学及断裂物理. 华中科技大学, 2003:143~148
48 何立民. 单片机应用系统设计与接口技术. 北京航空航天大学出版社, 1993
49 H. S. Stone. Microcomputer Interfacing. 机械工业出版社, 1992
50 张毅刚. MCS-51 系列单片机应用设计. 哈尔滨工业大学, 1998
2 T. Saotome, F. Yokoi. Precision Internal Threading of Stainless Steel. Precision Engineering, 1984,6(2):73~78
3 A. Bolden. Tapping Troubles. The Hidden Cause. Cutting Tool, 1990,3:8~12
4 韩荣第, 王扬. 现代机械加工新技术. 电子工业出版社, 2003:67~72
5 李海林, 王贵成. 低频振动攻丝提高加工精度的试验研究. 工艺与工艺装备, 2002,11:47~50
6 郑建明, 肖继明, 李言. 振动攻丝切削力及加工精度的研究. 西安理工大学学报, 2002,16(4):339~342
7 张春哗, 李海林, 王贵成. 采用振动攻丝提高工艺系统刚度的机理研究. 工具技术, 2003,37(3):11~13
8 B. Zhang, F. Yang. Fundamental Aspects in Vibration-Assisted Tapping. J. of Materials Processing Technology. 2003,132 :345~352
9 黄玉新, 黄友荣. 低频扭振攻丝加工的研究. 机械设计与制造, 2001(3):86~87
10 李祥林, 薛万夫. 振动切削及其在机械加工中的应用. 北京科学技术出版社, 1985:260~265
11 隈部纯一郎. 精密加工振动切削(基础与应用). 韩一昆译. 机械工业出版社, 1985:1~17
12 S. S. Patil, S. Pande. Some Investigations on Vibratory Tapping Process. Int. J. Mach. Tools Manufact. 1987,27(3):343~350
13 G. Hyatt. Innovation in Holemaking. Tool&Production, 1995,5:35~39
14 苟琪. 振动攻丝动态切削力研究. 中国机械工程, 1998,9(4):15~17
15 韩荣第, 刘建, 韩滨. SiCw/Al 铝复合材料振动攻丝扭矩的试验研究. 哈尔滨工业大学学报, 2002,34(4):30~34
16 王立平, 杨叔子. 变参数振动钻削提高微小孔加工精度的研究. 工具技术, 1998, 32(11):3~16
17 佟宇, 吴慧英. 用微机控制振动攻丝. 机械工艺师,1993(10)
18 M. L. Liu. Development of Next Generation Controller within Modern Manufacturing. Northeastern University Press, 1994:33~37
19 姜 大 志 , 孙 俊 兰 . 低 频 振 动 攻 丝 装 置 的 研 究 和 应 用 . 工 艺 装 备 ,2000,10:43~44
20 A. Shepherd. Top-Speed Tapping. Cutting Tool, 1991,3:39~48
21 殷宝麟, 韩荣第. 振动切削机理研究. 机械研究与应用, 2004,17(10):41~43
22 S. Eaetal. Vibratory Drilling of Holes in Stainless and Heat Resisting. Steel. Russian Eng. J., 1962,42(1):56
23 D. Jeong, I. Choi. Micro Surface Phenomenon of Ductile Cutting in Ultrasonic Vibration Cutting of Optical Plastics. J. Materials Processing Technology, 1997, 68:89~98
24 李海林, 王贵成. 低频振动攻丝技术. 机械设计与制造, 2003(1):87~89
25 叶大鹏, 何聪慧. 螺孔振动攻丝实验方法及其运动关系分析. 福建农业大学学报, 1999,28(4):505~508
26 王艺, 王朴. 振动切削在攻丝加工中的应用. 林业机械与木工设备, 1999,27 (5):26~28
27 韩荣第. 难加工材料切削加工. 机械工业出版社, 1996:46~65
28 苟琪, 陈鼎昌. 钛合金振动攻丝的切削扭矩模型. 机械研究与应用, 1997,3:18~21
29 张德远, 陈志同. 钛合金振动攻丝降低攻丝扭矩的研究. 机械工程学报, 1994,30(2):18~23
30 E. A . Nilkitin. Ultrasound Speeds up Thread Tapping Jobs. Soviet Engineering Research. 1989,9(4):118~119
31 周泽华. 金属切削原理. 上海科学技术出版社, 1993:60~65
32 C. W. Shul, K. Y. Lee. Dynamic Response of Subsurface Interface Crack in Multi-layered Orthotropic Half-space under Anti-plane Shear Impact Loading. Int. J. Solids and Structure, 2001,38(7):3563~3574
33 H. Qiu, M. Enoki. Effect of Pre-strain on Fracture Toughens of Ductile Structural Steels under Static and Dynamic Loading. Engineering Fracture Mechanics, 2005,72:1624~1633
34 王贵成, 李海林, 王树林, 裴宏杰. 低频振动攻丝丝锥动态角位移的研究. 机械工程师, 2003,14(9):1593~1596
35 Z. Lin, S. Li. A Study of Deformation of the Machined Work-piece and Tool under Different Low Cutting Velocities with an Elastic Cutting Tool. Int. J. Sci. , 1998,40:663~681
36 M. Lucas, G. Graham. Enhanced Vibration Control of an Ultrasonic CuttingProcess. Ultrasonic, 1996,34:205~211
37 王敏中. 弹性力学引论. 北京大学出版社, 2001:83~88
38 李光军, 张德远. 难加工材料的低频振动攻丝研究. 机械工程师, 2004,15(3):494~497
39 G. Eugene. Tapping Goes High-tech. Tool&Production, 1991,5: 35~39
40 X. Zhao. The Stress-intensity Factor for a Half Plane Crack in a Transversely Isotropic Solid Due to Impact Point Loading on the Crack Faces. Int. Journal of Solids and Structures, 2001,38:2851~2865
41 Q. Gou, Z. T. Chen. Research on Machining Titanium Alloys Blind Fastener. Journal of Qingdao University, 1997(10):55~59
42 W. Zhang. Fundamentals Elasticity Mechanics and Finite Element Method. Proc. Int. Mech. Engrs, 2003:206~211
43 D. Y. Zhang, Z. T. Chen. Relif-face Friction in Vibration Tapping. Int. J. Mech. Sci. , 1998,40(12):1209~1222
44 L. Wang. Prediction and Compute Simulation of Dynamic Thrust and Torque in Vibration Drilling. Proc. Int. Mech. Engrs. , 1998,212: 489~497
45 L. Cronjager and D. Meister. Drilling of Fiber and Particle Reinfored Alumin-inm. Composites Material Technology, 1991(1):37~45
46 T. Cao, J. Sutherland. Investigation of Thread Tapping Load Characteristics through Mechanistic Modeling and Experimentation. Int. J. Machine Tools and Manufacture, 2002,42:1527~1538
47 赵建生. 断裂力学及断裂物理. 华中科技大学, 2003:143~148
48 何立民. 单片机应用系统设计与接口技术. 北京航空航天大学出版社, 1993
49 H. S. Stone. Microcomputer Interfacing. 机械工业出版社, 1992
50 张毅刚. MCS-51 系列单片机应用设计. 哈尔滨工业大学, 1998