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2022 Vol. 65, No. 9
Published: 2022-05-01
FEATURE
FORUM
RESEARCH
C0NTENTS
COVER STORY
 
       COVER STORY
1 COVER
2022 Vol. 65 (9): 1-1 [Abstract] ( 75 ) HTMLNew PDF (2737 KB)  ( 50 )
       C0NTENTS
6 CONTENTS
2022 Vol. 65 (9): 6-10 [Abstract] ( 79 ) HTMLNew PDF (403 KB)  ( 37 )
       FEATURE
14 Analysis and Control of Nonlinear Error in Six-Axis Five-Linkage CNC Machining
SHA Zhihua，FENG Linlin，MA Fujian，SONG Xiuying，WANG Ziguang，ZHANG Shengfang
DOI: 10.16080/j.issn1671-833x.2022.09.014
Due to the inconsistency between the linear interpolation of CNC system and the actual tool path in multiaxis CNC machining, the nonlinear error is caused. In this study, the nonlinear error model is established to predict the position of the maximum nonlinear error, the parabola function method is used to further optimization the error model by analyzing the curve fitting degree, and the influence factors of nonlinear error are analyzed. The overerror program segment is controlled within the allowable value of error by adaptive linearization method. Taking the six-axis and five-linkage CNC machining of blade surface with disk knife as an example, the tool position file is simulated and analyzed. The nonlinear error of sampling program section is obviously improved after control, and the standard deviation of maximum nonlinear error is reduced by nearly 84.5%. The effectiveness of the above control method is verified.
2022 Vol. 65 (9): 14-19 [Abstract] ( 166 ) HTMLNew PDF (2109 KB)  ( 194 )
       COVER STORY
20 Development of High Performance Grinding Processes to Challenge Physical Limitations: Application Prospects in Aeronautical Manufacture Engineering
JIN Tan，HE Xun，WANG Qirong，SHANG Zhentao
DOI: 10.16080/j.issn1671-833x.2022.09.020
Grinding is widely applied in the aeronautical manufacture industry as an important process technique to guarantee the machining quality of those precision and ultra-precision components. Grinding has been developed into an enabling technology featuring high precision, high machining quality and also high process efficiency. It is capable to achieve high process efficiency with satisfactory machining accuracy and surface integrity. Driven by the application requirements and also the improvements of theoretical understanding, various high-performance grinding techniques have been developed beyond the limits of conventional grinding concepts. By using very high grinding wheel speeds, large depths of cut and also high worktable speeds, HEDG (High efficiency deep grinding) process can achieve extremely high machining efficiency, with good surface integrity on the ground workpiece surface. HEDG process has been successfully applied for the high efficiency grinding of turbine blade roots, showing excellent machining performance. HSSG (High speed stroke grinding) process is based on the linear drive technology for the worktable movement, pushing the feed rate toward an extremely high level, resulting in beneficial heat transfer conditions with most of the heat generated in the grinding zone being removed by the grinding chips, thus capable to achieve high grinding efficiency with good surface integrity. For the precision grinding of thin-walled slender shafts with high ratios of length over diameter, quick-point grinding technique provides the possibility to ensure both machining accuracy and machining efficiency. For the deepcut profile grinding of turbine blade roots using CFG (Creep-feed grinding) process, the heat transfer condition is rather complicated, further research work related with the heat transfer problems under the conditions of deep-cut and complex contact geometry is needed; Further research aspects also include process design method regarding the set up of parameters at different stages including roughing, semi-finishing and finishing, and intelligent process monitoring and optimization approaches. High efficiency deep grinding approach can also be applied for the deep-cut grinding of aluminum alloys widely used in aeronautical industry, whilst high speed and ultra-high speed grinding technique has good potentials to be applied for the machining of silicon carbide reinforced aluminum composites. High speed fly-grinding of the rotating blade tips assembled on the turbine disks, presents another application area of high speed and ultra-high speed grinding technique.
2022 Vol. 65 (9): 20-33 [Abstract] ( 157 ) HTMLNew PDF (8999 KB)  ( 121 )
       FORUM
36 Grinding Mechanism and Mechanical Chemical Grinding Experiment of Binderless Tungsten Carbide at Different Linear Speeds
ZHANG Zhenyu，ZHOU Chunchen，FENG Junyuan
DOI: 10.16080/j.issn1671-833x.2022.09.036
Glass molding has now become a popular method for mass production of optical lens. As an excellent mold material, binderless tungsten carbide has high hardness, strength, conductivity and thermal conductivity. However, due to its high brittleness, the binderless tungsten carbide is prone to cracking and breaking during processing, which making it difficult to obtain good surface quality and shape accuracy. In this paper, a high-speed scratching experiment was performed on an ultraprecision single-point turning machine. Scratching under linear velocities of 1m/s, 5m/s, 10m/s， and 20m/s were used to study the influence mechanism of the linear velocity on the removing form of tungsten carbide. Then ultra-precision grinding of tungsten carbide was carried out to study the surface morphology and sub-surface damage. Moreover, mechanical chemical grinding fluid is introduced to study its positive effect on the ground surface morphology of tungsten carbide. A water-based grinding fluid containing mass fraction 1% silicon oxide nanoparticles and 3% hydrogen peroxide was adopted during grinding. Finally, the surface morphology from mechanical chemical grinding was observed.
2022 Vol. 65 (9): 36-42 [Abstract] ( 152 ) HTMLNew PDF (75473 KB)  ( 112 )
43 Effect of Surface Structure on Grinding Performance of Internal Cooling Grinding Wheel
PENG Ruitao，GAO Shan，CHEN Meiliang，LIU Bo
DOI: 10.16080/j.issn1671-833x.2022.09.043
Aiming at the overheating and low machining efficiency problems in grinding superalloys, an internal cooling grinding wheel with a replaceable abrasive ring is proposed. To improve the flow characteristic and heat transfer performance of fluid in the grinding arc zone, surface structure of the ring and the internal flow channel outlet shape are designed based on the sunflower seed phyllotaxis configuration model. The flow field distribution model in grinding arc zone is established based on the computational fluid dynamics (CFD) method, finally the grinding tests of superalloy are carried out. Results indicate that abrasive cluster of phyllotaxis configuration leads to enhanced flow and cooling characteristics, compared with the circular flow channel, better cooling and lubrication effects are obtained by the rectangular flow channel, and the heat exchange efficiency is more remarkable as the grinding speed increases. Average grinding temperature and surface roughness of the workpiece are reduced by 24.12% and 18.50% respectively, and the machined surface morphology is smoother and more regular.
2022 Vol. 65 (9): 43-49/68 [Abstract] ( 124 ) HTMLNew PDF (60294 KB)  ( 93 )
50 Research on High-Effciency Precision Grinding of Structured Surfaces Based on Structured Grinding Wheels
GUO Bing，ZHANG Qinghe，GUO Zhenfei，AMR Monier，ZHAO Qingliang
DOI: 10.16080/j.issn1671-833x.2022.09.050
The paper mainly introduces the processing technology of the high-efficiency precision grinding of structured surfaces using structured grinding wheels. Firstly, the research status of grinding process based on structured grinding wheels for machining structured surfaces is summarized. Then, the solution method and simulation process to obtain the geometrical parameters of the structured surfaces in the grinding process are explained. Subsequently, a mathematical model of inversely solving the geometrical parameters of the structured grinding wheel and the corresponding grinding process parameters based on the designed structured surfaces is introduced. Finally, the accuracy and reliability of the established model are verified by experiments.
2022 Vol. 65 (9): 50-59 [Abstract] ( 127 ) HTMLNew PDF (21288 KB)  ( 80 )
60 Research on Contact Force Impedance Control Method of Blisk Grinding and Polishing Robot
LI Lun，WANG Zhengjia，ZHAO Jibin，ZHU Guang，ZHANG Hongyao
DOI: 10.16080/j.issn1671-833x.2022.09.060
2022 Vol. 65 (9): 60-68 [Abstract] ( 120 ) HTMLNew PDF (9529 KB)  ( 173 )
69 Research Progress on Precision and Ultra-Precision Grinding Mechanism and Key Technology on Sapphire Optical Elements With Complex Surface
WANG Sheng，ZHAO Qingliang，WANG Sheng，WANG Jinhu，QI Chunliang，WANG Jianyong
DOI: 10.16080/j.issn1671-833x.2022.09.069
Sapphire complex surface optical components are extensively utilized in high-end technology and aerospace fields due to their excellent mechanical and optical properties, while the high hardness and brittleness of sapphire and the high precision requirements of complex surfaces pose great challenges to optical fabrication capabilities. The research status of grinding mechanism and key manufacturing technology of sapphire complex surface optical components were reported. Firstly, the sapphire grinding mechanism was described in terms of sapphire material properties, surface subsurface damage, tool and tool wear, energy field assistance and residual stress, then the ultra-precision grinding processing technology of deep conformal rectifier and aspheric optical components of sapphire were investigated, and finally the key technology of sapphire free-form surface ultra-precision grinding processing was summarized and prospected.
2022 Vol. 65 (9): 69-80 [Abstract] ( 143 ) HTMLNew PDF (54449 KB)  ( 84 )
       RESEARCH
82 Research Advances in Hole Making Technology of Carbon Fiber Reinforced Plastics/Light Alloy Laminated Structure
BAI Dashan，CHEN Wuyi，CHEN Xuemei
DOI: 10.16080/j.issn1671-833x.2022.09.082
Carbon fber reinforced plastics/light alloy laminated structure has been extensively used in aerospace and related engineering felds. The research advances and development trends at home and abroad in hole making technology of carbon fber reinforced plastics/light alloy laminated structure were reviewed, mainly analyzing laminated structure drilling mechanisms, drilling-induced defects and influence factor of hole making quality. In order to realize the high-quality and high-effcient hole making of carbon fber reinforced plastics/light alloy laminated structure, the future study directions such as the modeling and simulation of cutting heat, prediction for hole making defects as well as intelligent control of drilling process are proposed. The current situation analysis and prospection of hole making research of laminated structure will contribute to the advances in technology in the feld of aircraft assembly.
2022 Vol. 65 (9): 82-88 [Abstract] ( 207 ) HTMLNew PDF (1238 KB)  ( 434 )
89 Research on 3D Visualization of Aircraft Component Assembly Progress Based on CATIA Composer
HAN Zhiren，LIU Xiaosong，WU Meng，LIU Baoming
DOI: 10.16080/j.issn1671-833x.2022.09.089
In order to solve the problem that the assembly status information feedback is not intuitive in the actual production site, to facilitate the management and avoid errors, and to ensure the realization of the progress goal, this paper proposes the use of CATIA Composer from the perspective of 3D visual display of assembly progress. The method of building a 3D display platform for assembly status of aircraft components by composer software is studied. The acquisition logic of assembly status of parts based on 3D AO and MES system is studied. The information model of assembly status of components is established. The display method of 3D model driven by assembly status of parts is put forward. The display process of assembly progress of aircraft components based on real-time production information is described. The central wing assembly workshop is used as an example to verify the feasibility of the method.
2022 Vol. 65 (9): 89-95 [Abstract] ( 169 ) HTMLNew PDF (9549 KB)  ( 118 )
96 Influence of Feed Velocity, Acceleration and Jerk on Processing Time of S–Shaped Fillet
Lü Dun，SONG Yanhong，LIU Yizhu，WANG Dawei，ZHAO?Wanhua
DOI: 10.16080/j.issn1671-833x.2022.09.096
In the processing of aerospace structural parts, in addition to the feed velocity, the feed acceleration and jerk also have an important influence on the processing time. Taking the fnishing process of the S–shaped fllet of the S–shaped test piece as an example, the influence of the feed velocity, acceleration and jerk on the processing time was studied using the Kede GNC61 CNC system. The possible effects of increasing velocity, acceleration and jerk on machine tool errors and S–shaped machining errors are analyzed. The results show that the increase of velocity, acceleration and jerk effectively reduces the processing time of S–shaped fllet. The feed velocity is increased from 1000mm/min to 5000mm/min, the acceleration is increased from 0.1m/s2 to 1.0m/s2, the acceleration establishment time is shortened from 200ms to 20ms, and the processing time of the S–shaped fllet is shortened by 24.20% , 25.38% and 41.84%. The problems caused by increasing speed, acceleration and jerk are increased setpoints bandwidth and increased excitation components. This makes it more diffcult to control the tracking error and trajectory error of the machine tool, and it is easy to excite the vibration of the machine tool mechanical structure.
2022 Vol. 65 (9): 96-102 [Abstract] ( 132 ) HTMLNew PDF (2177 KB)  ( 190 )
103 Residual Stresses of Al7050–T7451 Alloy Fastener Holes With Laser Shock Peening
SHUAI Shixiang，WU Junfeng，CHE Zhigang，CAO Ziwen，ZOU Shikun，SUN Rujian
DOI: 10.16080/j.issn1671-833x.2022.09.103
ABAQUS finite element model and life-death element technique were used to study the effects of  different laser shock peening (LSP) paths on the residual stresses of Al7050–T7451 alloy fastener holes, which would improve their fatigue lives. Fastener holes were treated by LSP before and after opening holes by numerical simulation and test study. The results indicate that the simulation values of S11 surface compressive residual stresses of Al7050–T7451 fastener holes treated by LSP with four spots are close to the test values and the simulation values with hole after are close to the test values. It verifes the correctness of the model. Compared with hole before, the high S11 surface compressive residual stresses are generated at the edge of Al7050–T7451 alloy fastener holes with hole after. Compared with the two transverse spots, the high S11 surface compressive residual stresses are generated at the edge of Al7050–T7451 fastener holes treated by LSP with two longitudinal spots. Compared with two spots, the high S11 surface compressive residual stresses are generated at the edge of Al7050–T7451 fastener holes treated by LSP with four spots. The results could lay the foundation for the fatigue extension of fastener holes with LSP.
2022 Vol. 65 (9): 103-109 [Abstract] ( 149 ) HTMLNew PDF (16685 KB)  ( 84 )
110 Simulation Investigation on Electromag
YANG Liu，YUE Ting，ZUO Yangjie，CAO Zengqiang，QIU Jiwei
DOI: 10.16080/j.issn1671-833x.2022.09.110
The installation of interference ft bolt is important for the interference ft long-life joining of aircraft. To optimize the electromagnetic force installation method of interference ft bolt, a fnite element model was developed to investigate the effects of key parameters on the interference ft bolt installation force in electromagnetic riveting method. The results showed that the charging voltage had a signifcant influence on the peak installation force, however, exhibited little influence on the force pulse width. Both the peak and pulse width of the installation force increased obviously with the increasing of the discharging capacitance at small discharging capacitance, however, the peak installation force was not sensitive to large discharging capacitance. The peak of the installation force decreased linearly with the increasing of the discharging resistance, while the pulse width of the installation force exhibited no relationship with the discharging resistance. Moreover, the peak of the installation force increased obviously with the early increasing thickness of the slave coil, then with the increasing of the thickness, the increasing rate of the peak decreased and fnally reached a constant. To obtain a suitable installation force in service, the large discharging capacitance and low discharging resistance are suggested, and the charging voltage is suggested to control the peak installation force.
2022 Vol. 65 (9): 110-114 [Abstract] ( 106 ) HTMLNew PDF (16359 KB)  ( 126 )
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