Abstract Hard and brittle materials such as quartz glass and engineering ceramics have excellent properties such as high temperature resistance, low expansion coefficient, thermal shock resistance and high chemical stability. They are widely used in aerospace, chemical, electronics, metallurgical and other industrial fields, but they are tough. And strength is different from elastoplastic metal materials, in addition...
Hard and brittle materials such as quartz glass and engineering ceramics have excellent properties such as high temperature resistance, low expansion coefficient, thermal shock resistance and high chemical stability. They are widely used in aerospace, chemical, electronics, metallurgical and other industrial fields, but such toughness and The strength is different from that of the elastoplastic metal material, and the load that the material bears during processing easily exceeds the elastic limit and breakage occurs. Therefore, the conventional processing method has low processing efficiency, severe tool wear, significant breakage and chipping, and high processing cost.
Rotary ultrasonic machining is an effective special processing method for the tool with diamond abrasive grains rotating along the axis, vibrating along the axial ultrasonic frequency and moving in the feed direction to interact with the processed material to achieve material removal. Technical difficulties in the processing of hard and brittle materials. Its material removal method is different from the direct mechanical grinding of the traditional grinding wheel, but the superposition of the diamond abrasive grains on the high-frequency vibration hammering, sliding rubbing, ploughing and abrasion of the workpiece. High-speed cutting and multi-axis machining are high-performance machining technologies in advanced manufacturing. High-speed cutting has the advantages of low cutting force, low cutting temperature, high machining efficiency and good surface quality. Multi-axis machining can solve the processing bottleneck that is difficult to achieve in low-dimensional machining. , to provide an effective solution for the manufacture of components containing complex profile features. The combination of rotary ultrasonic machining, high-speed cutting and multi-axis machining can effectively expand the technical advantages of each machining process.
The Laser and Intelligent Energy Field Manufacturing Team of the Advanced Manufacturing Institute of the Institute of Materials Technology and Engineering, Chinese Academy of Sciences has conducted a series of studies on multi-axis milling/rotating ultrasonic machining of hard and brittle materials. The research team closely combined with the team's advantages in the field of advanced materials laser processing, and for the technical requirements of hard and brittle materials processing in aerospace, optoelectronics and other fields, carried out a series of scientific mechanisms for rotating and ultrasonic machining of hard and brittle materials involving the optimization of the cutter axis vector. Process rules and optimization studies.
Researchers combine multi-axis high-speed milling with ultrasonic machining to further exploit the physical advantages of various manufacturing principles and technologies. In the multi-axis high-speed milling of elastoplastic materials, a series of preliminary basic researches were carried out. It was found that the multi-axis ball-milling tool-measurement index of the workpiece contact area changed significantly with the tool inclination angle, and the paper was submitted in the "Thirteenth Cutting and Advanced Manufacturing Technology". The Academic Conference (May 22-24, 2015, Taiyuan) reported (Key Engineering Materials, 2016, 693:788-794). Tool axis vector control is a key issue in multi-axis machining. Process optimization is a bridge for engineering applications. The inclination effect of surface quality directly affects the performance of the final molding surface. Therefore, the researchers studied the effects of dip and milling modes on surface quality, and conducted preliminary process optimization studies to refine the ideal process conditions. The relevant results were published in the manufacturing international journal (Int J Adv Manuf Tech, 2015, 77: 2035-2050.; Int J Adv Manuf Tech, 2016, DOI: 10.1007/s00170-016- 9143-x).
For hard and brittle materials such as quartz glass and engineering ceramics, the researchers conducted quartz glass rotary ultrasonic end milling test and finite element modeling and simulation. The relevant results will be published in the first issue of Tool Technology 2017; and confirmed by nanoindentation test. The quartz glass material will produce elastic recovery and plastic deformation after load excitation (in press, Procedia Engineering, Elsevier); the spatial motion trajectory of diamond abrasive particles is analyzed and the surface roughness and surface shape of the process parameters under multiaxial conditions are analyzed. The results show that the reasonable regulation of ultrasound and process parameters can achieve high-quality surface processing under the premise of improving efficiency, making full use of the advantages of ultrasound (in press, Procedia Engineering, Elsevier); Precision laser prefabricated micro-texture ultrasonic milling process and configuration method of processing system functional structure (invention patent 201510263505.1); for 99% alumina ceramics, laser micro-micron laser single-point multi-pulse process and ring-cut method Texture pretreatment, found that single point multi-pulse processing technology is easy to achieve high efficiency Small residual compressive stress pore array micro-texture processing, processing quality depends on spot quality, can improve the quality of the pit by optimizing the process parameters of the circumcision process, the processing aperture can be larger, and it is easy to produce greater residual compressive stress (in press , Procedia Engineering, Elsevier). Team members were invited to participate in the “2016 National Ultrasonic Processing Technology Symposium” (October 21-23, 2016, Dalian) and “13th Global Congress on Manufacturing and Management, GCMM 2016” (November 28-30, 2016, Zhengzhou), the relevant research results were presented at the conference, and received the attention of domestic and foreign counterparts.
The above work was supported by the National Natural Science Foundation of China Youth Science Fund Project (51505468), Ningbo Natural Science Foundation (2015A610104), China Postdoctoral Science Foundation Project (2015M571907) and the China Postdoctoral Science Foundation's ninth batch of special funding (2016T90555). .
