陶瓷基复合材料零部件的复杂曲面加工技术研究
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摘要
陶瓷基复合材料由于其优良的物理力学性能在切削工具、汽车、航空航天及仪器仪表等诸多领域都有广泛的应用前景。但由于陶瓷材料具有高硬度、高脆性和低断裂韧性等特点,是典型的难加工材料。特别是陶瓷材料复杂曲面的加工是长期以来希望解决、而至今仍未解决好的难题。
本文以航天领域广泛应用的陶瓷复合材料透波天线罩,发动机陶瓷关键部件等加工制造技术需求为背景,进行加工机理与工业生产工艺规范的研究。以获得一批达到工程应用的样件和一套陶瓷基复合材料零件加工制造的工艺规程。
以压痕断裂力学理论为基础,从微观上分析了工件的裂纹产生、成核、生长直到剥落的整个陶瓷材料去除的过程。阐述了陶瓷基复合材料的切削机理,为硬脆材料的机械加工技术提供了理论依据。
采用数学分析计算软件MATLAB/SIMULINK,对刀具与工件间作用力及其与刀具振动频率的关系进行了可视化研究,可获得工件加工过程的切削仿真结果。
论文针对陶瓷基复合材料复杂曲面零件的多轴数控超声波振动铣削加工技术进行了研究,主要对刀具转速、进给速度、分层厚度、刀具振动频率等参数作正交试验及其数据分析,得到了工艺参数的最优组合,初步形成了陶瓷基复合材料零件加工制造的工艺规程。加工出的整流罩等典型样件的尺寸、位置精度、表面质量均满足设计要求。
Because of CMC's superior physical and mechanical properties,it has extensive promising application in many fields, such as cutting tools, automobile, aerospace and apparatus. But ceramics is considered to be typical hard-to-machine material for its high hardness, brittleness and low fracture toughness. Especially the contour machining of ceramics is a difficult problem which is to be solved for a long time yet.
The research presented in this dissertation involves studies on machining mechanism and technologic criterion for industrial production, based on the machining technology requirement of the key ceramic parts'of wave-transparent radome made in the Ceramic Matrix Composite and engine in the field of aerospace. Finally a group of samples achieving engineering application and a set of technologic criterion which provided guidelines for manufacturing the Ceramic Matrix Composite were provided.
The indentation fracture mechanics theory, the force situation between ceramic materials and tools at the micro level and the analysis of the whole process of crack generation, nucleation, and growth until peeling off were concluded. The cutting nature of ceramic matrix composites was expounded, which provided theoretical support for machining high hardness, high brittleness material.
The feasibility of ceramic matrix composites surface complex multi-axis CNC machining of ultrasonic vibrations was validated. In order to study optimally on machining process of complex surface of SiO2 ceramic matrix composite of SiO2 fiber toughening, the cutting tool rotational speed, the feed rate, lamination thickness, the cutting tool vibrational frequency and Test Data Analysis and orthogonal test were carried on and obtained the most superior parameter combination finally. The cowlings and so on which was the typical sample work pieces developed by Topic-based group met the design requirements through the size, the position precision, surface quality's examination.
The visualization research of interplanting effort between cutting tool and work piece and cutting tool vibrational frequency were carried on using mathematical analysis computation software MATLAB/SIMULINK
Through the topic research, remarkable enhancement of production efficiency and work piece surface quality has been made, work piece which conformed to the design requirements and the technologic criterion of instrucing the scene production were performed. The topic research goal was achieved, which supplied a good base for the following related research work.
本文以航天领域广泛应用的陶瓷复合材料透波天线罩,发动机陶瓷关键部件等加工制造技术需求为背景,进行加工机理与工业生产工艺规范的研究。以获得一批达到工程应用的样件和一套陶瓷基复合材料零件加工制造的工艺规程。
以压痕断裂力学理论为基础,从微观上分析了工件的裂纹产生、成核、生长直到剥落的整个陶瓷材料去除的过程。阐述了陶瓷基复合材料的切削机理,为硬脆材料的机械加工技术提供了理论依据。
采用数学分析计算软件MATLAB/SIMULINK,对刀具与工件间作用力及其与刀具振动频率的关系进行了可视化研究,可获得工件加工过程的切削仿真结果。
论文针对陶瓷基复合材料复杂曲面零件的多轴数控超声波振动铣削加工技术进行了研究,主要对刀具转速、进给速度、分层厚度、刀具振动频率等参数作正交试验及其数据分析,得到了工艺参数的最优组合,初步形成了陶瓷基复合材料零件加工制造的工艺规程。加工出的整流罩等典型样件的尺寸、位置精度、表面质量均满足设计要求。
Because of CMC's superior physical and mechanical properties,it has extensive promising application in many fields, such as cutting tools, automobile, aerospace and apparatus. But ceramics is considered to be typical hard-to-machine material for its high hardness, brittleness and low fracture toughness. Especially the contour machining of ceramics is a difficult problem which is to be solved for a long time yet.
The research presented in this dissertation involves studies on machining mechanism and technologic criterion for industrial production, based on the machining technology requirement of the key ceramic parts'of wave-transparent radome made in the Ceramic Matrix Composite and engine in the field of aerospace. Finally a group of samples achieving engineering application and a set of technologic criterion which provided guidelines for manufacturing the Ceramic Matrix Composite were provided.
The indentation fracture mechanics theory, the force situation between ceramic materials and tools at the micro level and the analysis of the whole process of crack generation, nucleation, and growth until peeling off were concluded. The cutting nature of ceramic matrix composites was expounded, which provided theoretical support for machining high hardness, high brittleness material.
The feasibility of ceramic matrix composites surface complex multi-axis CNC machining of ultrasonic vibrations was validated. In order to study optimally on machining process of complex surface of SiO2 ceramic matrix composite of SiO2 fiber toughening, the cutting tool rotational speed, the feed rate, lamination thickness, the cutting tool vibrational frequency and Test Data Analysis and orthogonal test were carried on and obtained the most superior parameter combination finally. The cowlings and so on which was the typical sample work pieces developed by Topic-based group met the design requirements through the size, the position precision, surface quality's examination.
The visualization research of interplanting effort between cutting tool and work piece and cutting tool vibrational frequency were carried on using mathematical analysis computation software MATLAB/SIMULINK
Through the topic research, remarkable enhancement of production efficiency and work piece surface quality has been made, work piece which conformed to the design requirements and the technologic criterion of instrucing the scene production were performed. The topic research goal was achieved, which supplied a good base for the following related research work.
引文
[1]田欣利,于爱兵编著.工程陶瓷加工的理论与技术[M].北京：国防工业出版社出版,2006：1-3页
[2]樊新民,张聘,蒋丹宇编著.工程陶瓷及其应用[M].北京：机械工业出版社出版,2006：1-22页
[3]贾志新,艾冬梅等.工程陶瓷材料加工技术现状[J].机械工程材料,2000,24(1)：2-5页
[4]陈炳贻.陶瓷燃气轮机的技术开发[J].燃气涡轮试验与研究,1998,11(1)：48-53页
[5]尹衍升,陈守刚,李嘉等.先进结构陶瓷及其复合材料[M].北京：化学工业出版社,2006
[6]李要锋,刘传绍,赵波等.工程陶瓷叶轮的研究现状和发展趋势[J].水利电力机械,2006,6
[7]B. Schenk. Ceramic Turbine Engine Demonstration Project:A Summary Report. Journal of Engineering for Gas Turbines and Power,2002,124 (3):617-626P
[8]张玉军,张伟儒等编.结构陶瓷材料及其应用[M].北京：化学工业出版社出版,2005,3
[9]Hiroshi Kaya. The application of ceramic-matrix composites to the automotive ceramic gas turbine. Composites Science and Technology, 1999,59 (6):861-872P
[10]Takehara, T. Tatsumi, Y. Ichikawa, Summary of CGT302 Ceramic Gas Turbine Research and Development Program. Journal of Engineering for Gas Turbines and Power,2002,124 (3):627-635P
[11]于爱兵.发动机部件用陶瓷材料加工技术[J].汽车技术,1998,(5)：26-28页
[12]邓朝晖,张璧,孙宗禹等.陶瓷磨削材料去除机理的研究进展[J].中国机械工程,2002,13(18)：1608-1611页
[13]邓朝晖,张璧,孙宗禹等.陶瓷磨削的材料去除机理[J].金刚石与磨料磨具工程,2000,2(128)：47-51页
[14]Li K, Liav T W Surface/subsurface damage and the fracture strength of ground ceramics. Journal of Materials Processing Technology, 1996,57 (3-4):207-220P
[15]Z. J. Pei, P. M. Ferreira, M. Haselkorn, Plastic flow in rotary ultrasonic machining of ceramics, Journal of Materials Processing Technology,1995,48 (1-4):771-777P
[16]于思远,赵艳红,刘殿通.超声波振动加工工程陶瓷小孔的实验研究[J].电加工与模具,2001,4：31-34页
[17]Z.J.Pei, P.M.Ferreira. An experimental investigation of ultrasonic face milling, International Journal of Machine Tools & Manufacture, 1999,39 (8):1327-1344P
[18]D. G. LaChapelle, M. E. Noe, W. G. Edmondson, et al. CMC MATERIALS APPLICATIONSTO GAS TURBINE HOT SECTION COMPONENTS. AIAA-98-3266, Virginia:AIAA,1998:1-7P
[19]李成功,傅恒志,于翘等.航空航天材料[M].北京：国防工业出版社,2002
[20]B. Schenk. Ceramic Turbine Engine Demonstration Project:A Summary Report. Journal of Engineering for Gas Turbines and Power, 2002,124 (3):617-626P
[21]Ueda K,Sugita T,Tsuwa H.Applications of fracture mechanism in micro-cutting of engineering ceramics.Annals of the CIRP.1983,32 (1):83-86P
[22]廖永平,严擎宇.正交试验法在机械工业中的应用[M].北京：中国农业机械出版社,1982,8：5-21页
[23]杜则裕等编著.工程材料简明手册[M].北京：电子工业出版社,1996,9：412-427页
[24]张志涌等.精通MATLAB6.5版[M],北京：北京航空航天大学出版社,2003
[25]贾志新.工程陶瓷材料加工技术现状[J].机械工程材料,2000,(1)：2-5页
[26]赵福令,冯冬菊,史俊才等.陶瓷材料超声旋转加工技术[J].电加工与模具,2001,(1)：1-5页
[27]周旭,朱建林,向尕.集成化语言Matlab的Simulink仿真研究[J],湘潭大学自然科学学报,2003,22(1)：99-102页
[28]郭仁生编著.基于MATLAB和Pro/ENGINEER优化设计实例解析[M].北京：机械工业出版社,2007,7：1-21页
[29]王瑞刚,潘伟等.可加工陶瓷及工程陶瓷加工技术现状及发展[J].硅酸盐通报,2001,(3)：27-35页
[30]张立同,成来飞,徐永东.新型碳化硅陶瓷基复合材料的研究进展[J].航空制造技术2003,(1)：24-32页
[31]邹世钦,张长瑞,周新贵,曹英斌等.连续纤维增强陶瓷基复合材料在航空发动机上的应用[J].航空发动机,2005,31卷,(3)：55-58页
[32]黄春峰.工程陶瓷的加工技术[J].机械工程材料,2000,(1)：1-3页
[33]G.Ya,H.W.Qin,S.C.Ynag,Y.W.Xu.Annalysis of the rotary ultrasonic machining meehnaiesm. Jomual of Materials Processing teehnology, 2002,129:182-185P
[33]M.Komaariah,P-Narasimha Reddy.A study on the influence of wokrPiece Properties in ultrasonic machining.Intenrational journal of maehine tools and manufactuer,1993,33(3):495-505P
[34]秦华伟.旋转式超声波加工机理研究[硕士学位论文].太原理工大学,2001：7-33页
[35]龚江宏.陶瓷材料断裂力学[M].北京：清华大学出版社,2001,9：82-88页
[36]Q.H.zhang,J.H.Zhnag,Z.X.Jia et.. Material removal rate analysis in the ultrasonic cmachining of engineering cerics.Jounral of Materials processing Teehnology,1999,88:180-184P
[2]樊新民,张聘,蒋丹宇编著.工程陶瓷及其应用[M].北京：机械工业出版社出版,2006：1-22页
[3]贾志新,艾冬梅等.工程陶瓷材料加工技术现状[J].机械工程材料,2000,24(1)：2-5页
[4]陈炳贻.陶瓷燃气轮机的技术开发[J].燃气涡轮试验与研究,1998,11(1)：48-53页
[5]尹衍升,陈守刚,李嘉等.先进结构陶瓷及其复合材料[M].北京：化学工业出版社,2006
[6]李要锋,刘传绍,赵波等.工程陶瓷叶轮的研究现状和发展趋势[J].水利电力机械,2006,6
[7]B. Schenk. Ceramic Turbine Engine Demonstration Project:A Summary Report. Journal of Engineering for Gas Turbines and Power,2002,124 (3):617-626P
[8]张玉军,张伟儒等编.结构陶瓷材料及其应用[M].北京：化学工业出版社出版,2005,3
[9]Hiroshi Kaya. The application of ceramic-matrix composites to the automotive ceramic gas turbine. Composites Science and Technology, 1999,59 (6):861-872P
[10]Takehara, T. Tatsumi, Y. Ichikawa, Summary of CGT302 Ceramic Gas Turbine Research and Development Program. Journal of Engineering for Gas Turbines and Power,2002,124 (3):627-635P
[11]于爱兵.发动机部件用陶瓷材料加工技术[J].汽车技术,1998,(5)：26-28页
[12]邓朝晖,张璧,孙宗禹等.陶瓷磨削材料去除机理的研究进展[J].中国机械工程,2002,13(18)：1608-1611页
[13]邓朝晖,张璧,孙宗禹等.陶瓷磨削的材料去除机理[J].金刚石与磨料磨具工程,2000,2(128)：47-51页
[14]Li K, Liav T W Surface/subsurface damage and the fracture strength of ground ceramics. Journal of Materials Processing Technology, 1996,57 (3-4):207-220P
[15]Z. J. Pei, P. M. Ferreira, M. Haselkorn, Plastic flow in rotary ultrasonic machining of ceramics, Journal of Materials Processing Technology,1995,48 (1-4):771-777P
[16]于思远,赵艳红,刘殿通.超声波振动加工工程陶瓷小孔的实验研究[J].电加工与模具,2001,4：31-34页
[17]Z.J.Pei, P.M.Ferreira. An experimental investigation of ultrasonic face milling, International Journal of Machine Tools & Manufacture, 1999,39 (8):1327-1344P
[18]D. G. LaChapelle, M. E. Noe, W. G. Edmondson, et al. CMC MATERIALS APPLICATIONSTO GAS TURBINE HOT SECTION COMPONENTS. AIAA-98-3266, Virginia:AIAA,1998:1-7P
[19]李成功,傅恒志,于翘等.航空航天材料[M].北京：国防工业出版社,2002
[20]B. Schenk. Ceramic Turbine Engine Demonstration Project:A Summary Report. Journal of Engineering for Gas Turbines and Power, 2002,124 (3):617-626P
[21]Ueda K,Sugita T,Tsuwa H.Applications of fracture mechanism in micro-cutting of engineering ceramics.Annals of the CIRP.1983,32 (1):83-86P
[22]廖永平,严擎宇.正交试验法在机械工业中的应用[M].北京：中国农业机械出版社,1982,8：5-21页
[23]杜则裕等编著.工程材料简明手册[M].北京：电子工业出版社,1996,9：412-427页
[24]张志涌等.精通MATLAB6.5版[M],北京：北京航空航天大学出版社,2003
[25]贾志新.工程陶瓷材料加工技术现状[J].机械工程材料,2000,(1)：2-5页
[26]赵福令,冯冬菊,史俊才等.陶瓷材料超声旋转加工技术[J].电加工与模具,2001,(1)：1-5页
[27]周旭,朱建林,向尕.集成化语言Matlab的Simulink仿真研究[J],湘潭大学自然科学学报,2003,22(1)：99-102页
[28]郭仁生编著.基于MATLAB和Pro/ENGINEER优化设计实例解析[M].北京：机械工业出版社,2007,7：1-21页
[29]王瑞刚,潘伟等.可加工陶瓷及工程陶瓷加工技术现状及发展[J].硅酸盐通报,2001,(3)：27-35页
[30]张立同,成来飞,徐永东.新型碳化硅陶瓷基复合材料的研究进展[J].航空制造技术2003,(1)：24-32页
[31]邹世钦,张长瑞,周新贵,曹英斌等.连续纤维增强陶瓷基复合材料在航空发动机上的应用[J].航空发动机,2005,31卷,(3)：55-58页
[32]黄春峰.工程陶瓷的加工技术[J].机械工程材料,2000,(1)：1-3页
[33]G.Ya,H.W.Qin,S.C.Ynag,Y.W.Xu.Annalysis of the rotary ultrasonic machining meehnaiesm. Jomual of Materials Processing teehnology, 2002,129:182-185P
[33]M.Komaariah,P-Narasimha Reddy.A study on the influence of wokrPiece Properties in ultrasonic machining.Intenrational journal of maehine tools and manufactuer,1993,33(3):495-505P
[34]秦华伟.旋转式超声波加工机理研究[硕士学位论文].太原理工大学,2001：7-33页
[35]龚江宏.陶瓷材料断裂力学[M].北京：清华大学出版社,2001,9：82-88页
[36]Q.H.zhang,J.H.Zhnag,Z.X.Jia et.. Material removal rate analysis in the ultrasonic cmachining of engineering cerics.Jounral of Materials processing Teehnology,1999,88:180-184P