超声辅助加工系统研发及其在复合材料加工中的应用
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摘要
碳纤维复合材料在航空航天、国防军工、汽车、高速列车,以及体育与医疗器械等领域的应用越来越广泛。特别是用于航空航天领域的碳纤维复合材料复杂结构件和零部件的加工制造,对加工精度、质量和效率提出了很高的要求,传统机械加工方法和加工工具难以满足碳纤维复合材料的加工要求。超声辅助加工在降低切削力、提高表面加工质量和延长刀具寿命等方面具有优势,是适用于碳纤维复合材料加工的一种最为重要的方法。本文围绕超声辅助加工系统的关键技术开展相关研究,研制超声辅助车削加工装置和超声辅助磨削加工机床,并分别针对三维编织C/C复合材料和CFRP复合材料开展超声辅助车削和超声辅助磨削加工试验,分析超声辅助加工碳纤维复合材料的加工性能和加工效果。本论文的主要研究内容和研究成果如下：
(1)针对不同加工方式和不同工具形式,研究超声辅助加工变幅杆的设计方法。根据纵向振动的动力学理论和薄圆盘振动理论,分别建立超声辅助车削变幅杆以及采用小工具和大工具的超声辅助磨削变幅杆的设计方法。在此基础上,设计和研制适用于超声辅助车削和磨削加工的变幅杆。通过有限元分析和实际测试对所研制的超声变幅杆的振动性能进行研究,验证所建立的设计方法的正确性。
(2)针对旋转超声辅助加工对电能传输的需求和接触式电能传输中存在的问题,研究非接触式电能传输单元的设计方法。主要设计非接触式变压器,分析非接触式电能传输单元的匹配拓扑及特征,研究非接触式电能传输单元的匹配质量评价方法和谐振条件等。研制适用于旋转超声辅助加工的非接触式电能传输单元,并对其在额定功率下的传输性能进行测试,结果表明：在转速0～6000r·min-1范围内,随着转速的增加,非接触式电能传输单元的传输效率减小,且传输效率的减小率也逐渐变小
(3)根据超声辅助加工对超声电源的要求,研制适用于超声辅助加工的数字式智能超声电源。主要设计采用AD9850的高精度超声信号产生电路及其控制程序、基于效率较高的丁类功放电路的超声电源的功放电路、采用IR2110和半桥开关电路相结合的功放驱动电路。基于非接触传输单元原边电压和电流相位差为零的频率跟踪原理,设计采用MLT04模拟乘法器的频率跟踪电路及其控制程序。对研制的超声电源功率输出性能和频率跟踪性能进行测试。
(4)应用研制的超声振动系统,开发超声辅助车削装置。并应用所开发的装置进行超声辅助车削三维编织C/C复合材料的加工试验,根据三维编织C/C复合材料具有很强的非均质性和各向异性的特征,分析在不同径向位置超声辅助车削C/C复合材料加工表面不同周向位置的纤维分布特征,揭示C/C复合材料超声辅助车削加工表面形成机理,研究不同径向位置加工表面不同周向位置的表面质量变化规律,为C/C复合材料超声辅助车削表面质量评价提供了依据。进行超声辅助车削与普通车削三维编织C/C复合材料的对比试验,结果表明：超声辅助车削C/C复合材料可以显著提高表面质量,以及降低切削力、切削温度和刀具磨损等。
(5)应用研制的超声振动系统和非接触式超声电能传输技术研发超声辅助磨削机床,并进行超声辅助磨削CFRP复合材料的加工试验。通过观察分析CFRP复合材料加工后的表面形貌、切屑形貌和砂轮表面形貌,揭示超声辅助磨削加工碳纤维复合材料的加工机理。进行超声辅助磨削与普通磨削CFRP复合材料的对比试验,结果表明：超声辅助磨削可以显著降低磨削力,获得较好的表面质量,减少砂轮表面堵塞；超声辅助磨削加工的磨削力和表面粗糙度随加工时间的增大率,以及砂轮表面裸露磨粒密度随加工时间的减小率等明显小于普通磨削加工。
Carbon fiber composites are more and more widely used in the aircraft, automotive, high-speed trains, sports and health equipment etc. Especially, high accuracy, quality and efficiency are required for the manufacturing of complex structural parts and components in the aerospace field. The traditional machining methods and tools are difficult to meet the requirements of machining carbon fiber composites. Because of some advantages in decreasing the cutting force, improving the surface quality and extending tool life effectively, ultrasonic assisted machining is considered to be one of the most important methods to machine carbon fiber composites with high quality and efficiency. In this thesis, the key technologies of ultrasonic assisted machining system are researched. The ultrasonic assisted turning equipment and ultrasonic assisted grinding machine are developed. The experiments of ultrasonic assisted turning of carbon/carbon (C/C) composite and ultrasonic assisted grinding of carbon fiber reinforced polymer (CFRP) composite are carried out, and the performaces and effects of ultrasonic assisted machining carbon fiber composites are also discussed.The main research contents and results are as follows:
(1) For different machining methods and different types of tool, the design methods of the horn for ultrasonic assisted machining are studied. According to the dynamics theory of longitudinal vibration and, the design methods of the horns for ultrasonic assisted turning and ultrasonic assisted grinding with small grinding tools are researched. Furthermore, combining with the vibration theory of thin disc, the design methods of the horn for ultrasonic assisted grinding with big grinding tools are established. The horn for ultrasonic assisted turning and the horns for ultrasonic assisted grinding with small and big grinding tools are designed and developed individually. The vibration performances of the developed ultrasonic horns are researched by finite element modal analysis and practical test, and the established design methods are verified.
(2) For the requirement of the power transfer in rotary ultrasonic assisted machining, and the disadvangtes of contact power transfer, the design method of the contactless power transfer unit is set up. The contactless transformer is designd. The matching topologies and their characteristics of the contactless power transfer unit and their application range are discussed. The matching quality evaluation methods and the resonance conditions of contactless power transfer unit are established. A contactless power transfer unit which is suitable for ultrasonic assisted machining is developed. The transfer performances of contactless power transfer unit are tested at rated power, the results show that the transfer efficiency of contactless power transfer unit and decreases with the increase of rotating speed, and the deceasing ratio reduces gradually with that too.
(3) According to the demands for ultrasonic power supply of the ultrasonic assisted machining, a digital intelligent ultrasonic power supply which is suitable for ultrasonic assisted machining is developed. The high revolution ultrasonic signal generating circuit using AD9850and its control program are designed. The ultrasonic power amplifier circuit based on D power amplifier circuit and the driving circuit combined IR2110with half bridge switching circuit are designed. The frequency tracking method is researched based on the phase difference of the primary voltage and current of the contactless transfer unit. The frequency tracking circuit using MLT04analog multiplier and the control program of the tracking circuit are developed. The output and frequency tracking performances of ultrasonic power supply are tested.
(4) On the basis of the developed ultrasonic vibration system, an equipment of ultrasonic assisted turning is set up. The experiments of ultrasonic assisted turning of C/C composite are carried out. According to the non-homogeneity and anisotropy of three-dimensional woven C/C composite, the fiber distribution characteristics in the different circumference and radial on machined C/C composite surface are analyzed, the formation mechanism of the C/C composite surface after ultrasonic assisted turning is revealed, and the quality evaluation method of C/C composite surface after ultrasonic assisted turning is established. The comparive tests of ultrasonic assisted turning and common turning of C/C composite are carried out. the results show that the surface roughness, cutting force, the cutting temperature and tool wear are reduced significantly in ultrasonic assisted turning.
(5) Based on the developed ultrasonic vibration system, a computer numerical control ultrasonic assisted grinding machine is developed. The experiments of ultrasonic assisted grinding of CFRP composite are carried out. Through observing and analyzing the ground surface topography, chip shape and grinding wheel surface topography, the material removal mechanism of ultrasonic assisted grinding of CFRP composite is revealed. The comparive tests of ultrasonic assisted grinding and common grinding of CFRP composite are carried out, the results show that the cutting force is reduced significantly, and the surface quality is improved in ultrasonic assisted grinding. Furthermore, the increasing ratio of grinding force and surface roughness, and the decreasing ratio of the exposed abrasive density of grinding wheel surface of ultrasonic assisted grinding are significantly less than those of common grinding.
(1)针对不同加工方式和不同工具形式,研究超声辅助加工变幅杆的设计方法。根据纵向振动的动力学理论和薄圆盘振动理论,分别建立超声辅助车削变幅杆以及采用小工具和大工具的超声辅助磨削变幅杆的设计方法。在此基础上,设计和研制适用于超声辅助车削和磨削加工的变幅杆。通过有限元分析和实际测试对所研制的超声变幅杆的振动性能进行研究,验证所建立的设计方法的正确性。
(2)针对旋转超声辅助加工对电能传输的需求和接触式电能传输中存在的问题,研究非接触式电能传输单元的设计方法。主要设计非接触式变压器,分析非接触式电能传输单元的匹配拓扑及特征,研究非接触式电能传输单元的匹配质量评价方法和谐振条件等。研制适用于旋转超声辅助加工的非接触式电能传输单元,并对其在额定功率下的传输性能进行测试,结果表明：在转速0～6000r·min-1范围内,随着转速的增加,非接触式电能传输单元的传输效率减小,且传输效率的减小率也逐渐变小
(3)根据超声辅助加工对超声电源的要求,研制适用于超声辅助加工的数字式智能超声电源。主要设计采用AD9850的高精度超声信号产生电路及其控制程序、基于效率较高的丁类功放电路的超声电源的功放电路、采用IR2110和半桥开关电路相结合的功放驱动电路。基于非接触传输单元原边电压和电流相位差为零的频率跟踪原理,设计采用MLT04模拟乘法器的频率跟踪电路及其控制程序。对研制的超声电源功率输出性能和频率跟踪性能进行测试。
(4)应用研制的超声振动系统,开发超声辅助车削装置。并应用所开发的装置进行超声辅助车削三维编织C/C复合材料的加工试验,根据三维编织C/C复合材料具有很强的非均质性和各向异性的特征,分析在不同径向位置超声辅助车削C/C复合材料加工表面不同周向位置的纤维分布特征,揭示C/C复合材料超声辅助车削加工表面形成机理,研究不同径向位置加工表面不同周向位置的表面质量变化规律,为C/C复合材料超声辅助车削表面质量评价提供了依据。进行超声辅助车削与普通车削三维编织C/C复合材料的对比试验,结果表明：超声辅助车削C/C复合材料可以显著提高表面质量,以及降低切削力、切削温度和刀具磨损等。
(5)应用研制的超声振动系统和非接触式超声电能传输技术研发超声辅助磨削机床,并进行超声辅助磨削CFRP复合材料的加工试验。通过观察分析CFRP复合材料加工后的表面形貌、切屑形貌和砂轮表面形貌,揭示超声辅助磨削加工碳纤维复合材料的加工机理。进行超声辅助磨削与普通磨削CFRP复合材料的对比试验,结果表明：超声辅助磨削可以显著降低磨削力,获得较好的表面质量,减少砂轮表面堵塞；超声辅助磨削加工的磨削力和表面粗糙度随加工时间的增大率,以及砂轮表面裸露磨粒密度随加工时间的减小率等明显小于普通磨削加工。
Carbon fiber composites are more and more widely used in the aircraft, automotive, high-speed trains, sports and health equipment etc. Especially, high accuracy, quality and efficiency are required for the manufacturing of complex structural parts and components in the aerospace field. The traditional machining methods and tools are difficult to meet the requirements of machining carbon fiber composites. Because of some advantages in decreasing the cutting force, improving the surface quality and extending tool life effectively, ultrasonic assisted machining is considered to be one of the most important methods to machine carbon fiber composites with high quality and efficiency. In this thesis, the key technologies of ultrasonic assisted machining system are researched. The ultrasonic assisted turning equipment and ultrasonic assisted grinding machine are developed. The experiments of ultrasonic assisted turning of carbon/carbon (C/C) composite and ultrasonic assisted grinding of carbon fiber reinforced polymer (CFRP) composite are carried out, and the performaces and effects of ultrasonic assisted machining carbon fiber composites are also discussed.The main research contents and results are as follows:
(1) For different machining methods and different types of tool, the design methods of the horn for ultrasonic assisted machining are studied. According to the dynamics theory of longitudinal vibration and, the design methods of the horns for ultrasonic assisted turning and ultrasonic assisted grinding with small grinding tools are researched. Furthermore, combining with the vibration theory of thin disc, the design methods of the horn for ultrasonic assisted grinding with big grinding tools are established. The horn for ultrasonic assisted turning and the horns for ultrasonic assisted grinding with small and big grinding tools are designed and developed individually. The vibration performances of the developed ultrasonic horns are researched by finite element modal analysis and practical test, and the established design methods are verified.
(2) For the requirement of the power transfer in rotary ultrasonic assisted machining, and the disadvangtes of contact power transfer, the design method of the contactless power transfer unit is set up. The contactless transformer is designd. The matching topologies and their characteristics of the contactless power transfer unit and their application range are discussed. The matching quality evaluation methods and the resonance conditions of contactless power transfer unit are established. A contactless power transfer unit which is suitable for ultrasonic assisted machining is developed. The transfer performances of contactless power transfer unit are tested at rated power, the results show that the transfer efficiency of contactless power transfer unit and decreases with the increase of rotating speed, and the deceasing ratio reduces gradually with that too.
(3) According to the demands for ultrasonic power supply of the ultrasonic assisted machining, a digital intelligent ultrasonic power supply which is suitable for ultrasonic assisted machining is developed. The high revolution ultrasonic signal generating circuit using AD9850and its control program are designed. The ultrasonic power amplifier circuit based on D power amplifier circuit and the driving circuit combined IR2110with half bridge switching circuit are designed. The frequency tracking method is researched based on the phase difference of the primary voltage and current of the contactless transfer unit. The frequency tracking circuit using MLT04analog multiplier and the control program of the tracking circuit are developed. The output and frequency tracking performances of ultrasonic power supply are tested.
(4) On the basis of the developed ultrasonic vibration system, an equipment of ultrasonic assisted turning is set up. The experiments of ultrasonic assisted turning of C/C composite are carried out. According to the non-homogeneity and anisotropy of three-dimensional woven C/C composite, the fiber distribution characteristics in the different circumference and radial on machined C/C composite surface are analyzed, the formation mechanism of the C/C composite surface after ultrasonic assisted turning is revealed, and the quality evaluation method of C/C composite surface after ultrasonic assisted turning is established. The comparive tests of ultrasonic assisted turning and common turning of C/C composite are carried out. the results show that the surface roughness, cutting force, the cutting temperature and tool wear are reduced significantly in ultrasonic assisted turning.
(5) Based on the developed ultrasonic vibration system, a computer numerical control ultrasonic assisted grinding machine is developed. The experiments of ultrasonic assisted grinding of CFRP composite are carried out. Through observing and analyzing the ground surface topography, chip shape and grinding wheel surface topography, the material removal mechanism of ultrasonic assisted grinding of CFRP composite is revealed. The comparive tests of ultrasonic assisted grinding and common grinding of CFRP composite are carried out, the results show that the cutting force is reduced significantly, and the surface quality is improved in ultrasonic assisted grinding. Furthermore, the increasing ratio of grinding force and surface roughness, and the decreasing ratio of the exposed abrasive density of grinding wheel surface of ultrasonic assisted grinding are significantly less than those of common grinding.
引文
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