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外文資料及譯文
Special processing Generality
Special processing which is also called "non-traditional machining" or "modern processing method", referring to electrical energy, heat energy, light energy, electrochemistry energy, chemical energy, sound energy and mechanical energy, such as special processing methods to remove or add material energy. Special processing technology is mainly described in this article refers to the laser processing technology, electron beam processing technology, ion beam and plasma processing technology and processing technology, etc.
With the development of new type weapons and equipment, the increasingly urgent demand for special processing technology at home and abroad. Both aircraft, missiles, and other combat platforms are required to reduce the structure weight, improve the speed, increased range, reduce fuel consumption, achieve lighter high performance, structure, long service life and good economic affordability. To this end, the weapon system and combat platforms are required to use integral structure, lightweight structure, the new structure, advanced cooling structure and titanium alloys, composite materials, powder materials, intermetallic compounds, such as new materials.
To do this, you need the special processing technology, equipment manufacturing, in order to solve processing problem of using conventional processing methods cannot be achieved, so special processing technology is the main application areas:
Difficult-to-machine materials, such as high strength steel, titanium alloy, heat-resistant stainless steel, composite materials, engineering ceramics, diamond, ruby, hardened glass high hardness, high toughness, high strength, high melting point materials.
Difficult machining parts, such as complex parts 3 d cavity type, hole processing, group of hole and narrow gap, etc.
Low rigidity parts, such as thin walled parts, elastic element and other parts of the processing.
With high energy density beam for welding, cutting, making holes, spraying, surface modification, etching and fine processing.
1. The laser processing technology
Laser processing equipment and processes abroad has developed rapidly, now has 100 kW high power CO 2 laser , kW level high beam quality of Nd: YAG solid laser, some with optical fiber can be transfer, telecommuting. Big power laser processing equipment, high automatic degree and has been widely used CNC control, multi-axis linkage, and is equipped with laser power monitoring, automatic focusing, industrial TV shows and other auxiliary system.
Laser hole of minimum aperture has amounted to 0.002 mm, has succeeded in application of automation system of six coordinate laser hole special equipment for processing, with holes on the combustion chamber, gas turbine engine to achieve to cast layer, the effect of the micro cracks.
Laser cutting is suitable for the made of heat resistant alloy, titanium alloy, composite material parts. Currently BoCai cutting speed can be up to 15 m/min, narrow kerf width, generally between 0.1 ~ 1 mm, heat affected zone is only 10% ~ 20% of the kerf width, maximum cutting thickness of 45 mm, has been widely used in plane three-dimensional skin ship plate, frame, ships and helicopter rotor, engine combustion chamber, etc.
Laser welding thin plate has been quite common, most are employed in the automotive industry, aerospace and instrumentation industries. Laser subtle welding technology has become an aviation electronic equipment, high precision mechanical equipment in the micro encapsulation nodes one important means of micro connection.
Laser surface strengthening, surface remelting, alloying, amorphous processing technology application is more and more widely, laser microfabrication applications in electronics, biology, medical engineering has become an irreplaceable special processing technology.
Laser rapid prototyping technology has expanded from research and development stage to application stage, has shown broad application prospects.
At home in the early 70 s has begun for laser processing applied research, but the development speed is slow. Hole in the laser system, laser heat treatment, welding, etc. Although have a certain application, but the quality is not stable. Has developed a solid laser processing systems with optical fiber transmission, and realize the optical fiber coupling synchronization of the three beams welding and laser welding of quartz watch movements. Completed the laser sintering rapid prototyping principle prototype, and with polyester and epoxy resin sand sintered powder materials, rapid prototyping of typical parts, such as impeller, the gear.
Laser processing technology in the next few years should combine pre-study achievements have been achieved, according to demand, focus on zero defect laser processing of gas membrane pores and control technology of real-time detection, high strength aluminum) (lithium containing aluminum, aluminum and magnesium alloy laser welding technology, laser sintering rapid prototyping technology, powder of metal parts laser precision machining and important component of the research of laser shock processing, etc. Achieve zero defect with holes on the high temperature turbine engine processing, can make the blade service life of 2000 hours; To welding instead of nc machining plane bearing components, as well as welding for riveting of ribbed wall; Realize the important parts of surface strengthening, improve security, reliability, etc., so that advanced laser manufacturing technology play a more important role in military industry.
2. The electron beam processing technology
Electron beam processing technology become more mature in the world, wide application range. Finalize the design production abroad 40 kv ~ 300 kv electron gun (mainly including 60 kv, 150 kv), has been widely used CNC control, multi-axis linkage, a high degree of automation. Electron beam welding has been successfully used in special materials, dissimilar materials, complex space curve, non-uniform welding, etc. Is currently studying weld automatic tracking, wire filling welding, vacuum welding, such as maximum welding penetration of up to 300 mm, deep weld width than those days. Electron beam welding has been used in space shuttle launch vehicle, the main bearing components are large structures such as the combination of welding, as well as the aircraft beam, box, landing gear parts, whole engine rotor shaft, casing, power and other important structures and nuclear power plant pressure vessel manufacturing. Such as the f-22 fighter with advanced electron beam welding, reduce aircraft weight, improve the performance of the machine; "Su - 27" and other series of large bearing components, such as the gear, the load bearing frame, adopts high voltage electron beam welding technology.
Domestic various types of aircraft and engines and a variety of models of the missile shell, oil tank, the exhaust structures have been adopted the electron beam welding. Therefore, the application of electron beam welding technology is more and more widely, the demand for electron beam welding equipment is becoming more and more big.
Electron beam welder abroad to Germany, the United States, France, Ukraine, etc, have reached the engineering production. Is characterized by variable frequency power supply, the volume of equipment, noise, and high pressure performance is greatly improved; In terms of control system, using advanced computer technology, adopts the advanced CNC and PLC technology, make the control more reliable, equipment operation more simple and intuitive.
Vacuum electron beam physical vapor deposition technology abroad, have been used for aeroengine turbine blade high temperature anti-corrosion insulation ceramic coating, to improve the thermal shock resistance of the coating and the life. Electron beam lithography and electron beam irradiation curing resin matrix composites technology is at the research stage.
Electron beam processing technology in the future should actively expand professional field, closely tracking the international advanced technology development, in view of the demand, focus on key techniques of electron beam physical vapor deposition, the main bearing structure electron beam welding, electron beam irradiation curing technology study, key techniques of electron beam welding machine, etc.
3. The ion beam and plasma processing technology
Function of surface coating has high hardness, wear resistance, corrosion resistance function, can significantly improve the life of the parts, with wide USES in industry.
Currently in the United States and European countries most use microwave ECR plasma source to the preparation of various functional coatings. Plasma body spraying technology already in engineering application, has been widely used in aviation, aerospace, ships, etc. Products are key components in the field of wear-resistant coating, seal coating, thermal barrier coating and heat shielding layer, etc.
Plasma welding has been successfully applied to 18 mm storage tank welding of aluminum alloy. Equipped with robots and plasma welding seam tracking system in complex space welding seam has practical application. Microbeam plasma welding are widely used in precision components of welding. Plasma spraying has been applied to weapons and equipment of developed in our country, mainly used in wear-resistant coating, seal coating, high temperature protection coating and thermal barrier coating.
Vacuum plasma spraying technology and omni-directional ion implantation technology has begun to study, with abroad still has big distance. Plasma welding is used in the production, but the welding quality is not stable.
Ion beam and plasma processing technology in the future should be combined with the results have been achieved, according to demand, and ion implantation on the thermal barrier coating on the surface modification of the new technology research, at the same time, on the basis of the already obtained preliminary results, further research on plasma welding technology.
4. Electric processing technology
Widely used abroad, electrochemical machining, in addition to the blade and the integral impeller has expanded to the casing, the plate of ring parts and deep hole processing, using electrochemical machining can work out high precision metal reflective mirror. Current electrochemical machining machine tool capacity has reached 50000 amps, and has set up a CNC control and multiple parameter adaptive control. With holes on the electrical discharge machining using multi-channel and nanosecond ultra high frequency pulse power and electrode processing of special equipment at the same time, more 2 ~ 3 seconds/hole machining efficiency, surface roughness Ra0.4 microns, general high-grade electric spark forming and cutting has been able to provide micron grade machining precision, can be processed 3 microns of micro hole axis and 5 microns. Precision pulse electrolysis technology has amounted to about 10 microns. Electrolysis with edm compound machining and electrolytic grinding, edm grinding has been used in production.
According to the status quo, the development direction of special processing technology should be:
(1) continuous improvement, improve the quality of the high energy beam source, and to develop in the direction of high power, high reliability.
(2) high energy beam machining equipment to muti_function, motors and intelligent direction, makes every effort to achieve the goal of standardization, seriation and modularization. Expand the application scope, to develop in the direction of composite processing.
(3) is steadily high energy beam machining new technologies, new processes, new equipment engineering and industrialization of work.
Above to achieve development goals, must carry out the following processing technology research:
(1) laser processing technology
Micro cracks to cast layer, efficient laser processing technology research with holes on the turbine blades;
titanium alloy, aluminum alloy, super steel dissimilar material artifacts and laser welding process of large curved surface parts research, three-dimensional laser cutting process specification and surface quality of the online measuring control technology and control technology research and improve the high temperature alloy, aluminium alloy, and other important components impact fatigue resistance of laser technology research; High-power laser rapid prototyping technology research, laser cladding ceramic coating technology and coating structure and performance study.
(2) electron beam processing technology
150 kv and 15 kw high pressure gun and high voltage power supply technology research;
Electron beam physical vapor deposition technology research;
Large thickness of the cross-section of electron beam welding technology of titanium alloy research and quality evaluation;
Typical electron beam curing process of composite aircraft components research and engineering research;
Multifunctional electron beam processing technology research.
(3) the ion beam and plasma processing technology
Complex parts "conformal implantation and mixed deposition technology research, to obtain high density plasma method research; Spatial structure of welding technology parameter adaptive control and weld automatic tracking system, in the process of the plasma arc welding and deformation control technology research; Plasma spraying ceramic thermal barrier coating structure, technology and engineering research; Laminar-turbulent automatic conversion technology and axial feeding, three-dimensional spraying technology research; Laminar plasma spraying, system development and its spraying technology research.
(4) machining technology
High quality deep hole electro-hydraulic beam processing technology research;
High efficiency, high quality photographic electrochemical machining technology research group of hole;
Multi-spindle, multi-channel electrical discharge machining of holes, special-shaped hole technology research;
The large capacity (5000 a and above) precision electrochemical machining technology research;
Electrolysis - edm compound machining technology research.
Study the technical key is: improve the quality of the high energy beam; To carry out special processing of automatic control and computer modeling and simulation technology research; New materials processing characteristics research; Research of special processing equipment, etc.
特種加工概論
特種加工亦稱“非傳統(tǒng)加工”或“現(xiàn)代加工方法”，泛指用電能、熱能、光能、電化學能、化學能、聲能及特殊機械能等能量達到去除或增加材料的加工方法。本文所述的特種加工技術(shù)主要是指激光加工技術(shù)、電子束加工技術(shù)、離子束及等離子加工技術(shù)和電加工技術(shù)等。
隨著新型武器裝備的發(fā)展，國內(nèi)外對特種加工技術(shù)的需求日益迫切。不論飛機、導彈，還是其它作戰(zhàn)平臺都要求降低結(jié)構(gòu)重量，提高飛行速度，增大航程，降低燃油消耗，達到戰(zhàn)技性能高、結(jié)構(gòu)壽命長、經(jīng)濟可承受性好。為此，上述武器系統(tǒng)和作戰(zhàn)平臺都要求采用整體結(jié)構(gòu)、輕量化結(jié)構(gòu)、先進冷卻結(jié)構(gòu)等新型結(jié)構(gòu)，以及鈦合金、復合材料、粉末材料、金屬間化合物等新材料。
為此，需要采用特種加工技術(shù)，以解決武器裝備制造中用常規(guī)加工方法無法實現(xiàn)的加工難題，所以特種加工技術(shù)的主要應用領(lǐng)域是：
難加工材料，如鈦合金、耐熱不銹鋼、高強鋼、復合材料、工程陶瓷、金剛石、紅寶石、硬化玻璃等高硬度、高韌性、高強度、高熔點材料。
難加工零件，如復雜零件三維型腔、型孔、群孔和窄縫等的加工。
剛度零件，如薄壁零件、彈性元件等零件的加工。
高能量密度束流實現(xiàn)焊接、切割、制孔、噴涂、表面改性、刻蝕和精細加
1. 激光加工技術(shù)
國外激光加工設(shè)備和工藝發(fā)展迅速，現(xiàn)已擁有100kW的大功率CO2激光器、kW級高光束質(zhì)量的Nd:YAG固體激光器，有的可配上光導纖維進行多工位、遠距離工作。激光加工設(shè)備功率大、自動化程度高，已普遍采用CNC控制、多坐標聯(lián)動，并裝有激光功率監(jiān)控、自動聚焦、工業(yè)電視顯示等輔助系統(tǒng)。
激光制孔的最小孔徑已達0.002mm，已成功地應用自動化六坐標激光制孔專用設(shè)備加工航空發(fā)動機渦輪葉片、燃燒室氣膜孔，達到無再鑄層、無微裂紋的效果。
激光切割適用于由耐熱合金、鈦合金、復合材料制成的零件。目前薄材切割速度可達15m/min，切縫窄，一般在0.1～1mm之間，熱影響區(qū)只有切縫寬的10%～20%，最大切割厚度可達45mm，已廣泛應用于飛機三維蒙皮、框架、艦船船身板架、直升機旋翼、發(fā)動機燃燒室等。
激光焊接薄板已相當普遍，大部分用于汽車工業(yè)、宇航和儀表工業(yè)。激光精微焊接技術(shù)已成為航空電子設(shè)備、高精密機械設(shè)備中微型件封裝結(jié)點的微型連接的重要手段。
激光表面強化、表面重熔、合金化、非晶化處理技術(shù)應用越來越廣，激光微細加工在電子、生物、醫(yī)療工程方面的應用已成為無可替代的特種加工技術(shù)。
激光快速成型技術(shù)已從研究開發(fā)階段發(fā)展到實際應用階段，已顯示出廣闊的應用前景。
國內(nèi)70年代初已開始進行激光加工的應用研究，但發(fā)展速度緩慢。在激光制孔、激光熱處理、焊接等方面雖有一定的應用，但質(zhì)量不穩(wěn)定。目前已研制出具有光纖傳輸?shù)墓腆w激光加工系統(tǒng)，并實現(xiàn)光纖耦合三光束的同步焊接和石英表芯的激光焊接。完成了激光燒結(jié)快速成型原理樣機研制，并采用環(huán)氧聚脂和樹脂砂燒結(jié)粉末材料，快速成型出典型零件，如葉輪、齒輪。
激光加工技術(shù)今后幾年應結(jié)合已取得的預研成果，針對需求，重點開展無缺陷氣膜小孔的激光加工及實時檢控技術(shù)、高強鋁(含鋁鋰、鋁鎂)合金的激光焊接技術(shù)、金屬零件的激光粉末燒結(jié)快速成型技術(shù)、激光精密加工及重要構(gòu)件的激光沖擊強化等項目的研究。實現(xiàn)高溫渦輪發(fā)動機氣膜孔無缺陷加工，可使葉片使用壽命達2000小時以上；以焊代替數(shù)控加工飛機次承力構(gòu)件，以及帶筋壁板的以焊代鉚；實現(xiàn)重要零部件的表面強化，提高安全性、可靠性等，從而使先進的激光制造技術(shù)在軍事工業(yè)中發(fā)揮更大的作用。
2.電子束加工技術(shù)
電子束加工技術(shù)在國際上日趨成熟，應用范圍廣。國外定型生產(chǎn)的40kV～300kV的電子槍(以60kV、150kV為主)，已普遍采用CNC控制，多坐標聯(lián)動，自動化程度高。電子束焊接已成功地應用在特種材料、異種材料、空間復雜曲線、變截面焊接等方面。目前正在研究焊縫自動跟蹤、填絲焊接、非真空焊接等，最大焊接熔深可達300mm，焊縫深寬比20：1。電子束焊已用于運載火箭、航天飛機等主承力構(gòu)件大型結(jié)構(gòu)的組合焊接，以及飛機梁、框、起落架部件、發(fā)動機整體轉(zhuǎn)子、機匣、功率軸等重要結(jié)構(gòu)件和核動力裝置壓力容器的制造。如：F-22戰(zhàn)斗機采用先進的電子束焊接，減輕了飛機重量，提高了整機的性能；“蘇-27”及其它系列飛機中的大量承力構(gòu)件，如起落架、承力隔框等，均采用了高壓電子束焊接技術(shù)。
國內(nèi)多種型號的飛機及發(fā)動機和多種型號的導彈殼體、油箱、尾噴管等結(jié)構(gòu)件均已采用了電子束焊接。因此，電子束焊接技術(shù)的應用越來越廣泛，對電子束焊接設(shè)備的需求量也越來越大。
國外的電子束焊機，以德國、美國、法國、烏克蘭等為代表，已達到了工程化生產(chǎn)。其特點是采用變頻電源，設(shè)備的體積、噪聲、高壓性能等方面都有很大提高；在控制系統(tǒng)方面，運用了先進的計算機技術(shù)，采用了先進的CNC及PLC技術(shù)，使設(shè)備的控制更可靠，操作更簡便、直觀。
國外真空電子束物理氣相沉積技術(shù)，已用于航空發(fā)動機渦輪葉片高溫防腐隔熱陶瓷涂層，提高了涂層的抗熱沖擊。
性能及壽命。電子束刻蝕、電子束輻照固化樹脂基復合材料技術(shù)正處于研究階段。電子束加工技術(shù)今后應積極拓展專業(yè)領(lǐng)域，緊密跟蹤國際先進技術(shù)的發(fā)展，針對需求，重點開展電子束物理氣相沉積關(guān)鍵技術(shù)研究、主承力結(jié)構(gòu)件電子束焊接研究、電子束輻照固化技術(shù)研究、電子束焊機關(guān)鍵技術(shù)研究等。
3.離子束及等離子體加工技術(shù)
表面功能涂層具有高硬度、耐磨、抗蝕功能，可顯著提高零件的壽命，在工業(yè)上具有廣泛用途。
美國及歐洲國家目前多數(shù)用微波ECR等離子體源來制備各種功能涂層。等離子體熱噴涂技術(shù)已經(jīng)進入工程化應用，已廣泛應用在航空、航天、船舶等領(lǐng)域的產(chǎn)品關(guān)鍵零部件耐磨涂層、封嚴涂層、熱障涂層和高溫防護層等方面。
等離子焊接已成功應用于18mm鋁合金的儲箱焊接。配有機器人和焊縫跟蹤系統(tǒng)的等離子體焊在空間復雜焊縫的焊接也已實用化。微束等離子體焊在精密零部件的焊接中應用廣泛。我國等離子體噴涂已應用于武器裝備的研制，主要用于耐磨涂層、封嚴涂層、熱障涂層和高溫防護涂層等。
真空等離子體噴涂技術(shù)和全方位離子注入技術(shù)已開始研究，與國外尚有較大差距。等離子體焊接在生產(chǎn)中雖有應用，但焊接質(zhì)量不穩(wěn)定。
離子束及等離子體加工技術(shù)今后應結(jié)合已取得的成果，針對需求，重點開展熱障涂層及離子注入表面改性的新技術(shù)研究，同時，在已取得初步成果的基礎(chǔ)上，進一步開展等離子體焊接技術(shù)研究。
4. 電加工技術(shù)
國外電解加工應用較廣，除葉片和整體葉輪外已擴大到機匣、盤環(huán)零件和深小孔加工，用電解加工可加工出高精度金屬反射鏡面。目前電解加工機床最大容量已達到5萬安培，并已實現(xiàn)CNC控制和多參數(shù)自適應控制。電火花加工氣膜孔采用多通道、納秒級超高頻脈沖電源和多電極同時加工的專用設(shè)備，加工效率2～3秒/孔，表面粗糙度Ra0.4μm，通用高檔電火花成型及線切割已能提供微米級加工精度，可加工3μm的微細軸和5μm的孔。精密脈沖電解技術(shù)已達10μm左右。電解與電火花復合加工，電解磨削、電火花磨削已用于生產(chǎn)。
根據(jù)上述現(xiàn)狀，今后特種加工技術(shù)的發(fā)展方向應是：
(1)不斷改進、提高高能束源品質(zhì)，并向大功率、高可靠性方向發(fā)展。
(2)高能束流加工設(shè)備向多功能、精密化和智能化方向發(fā)展，力求達到標準化、系列化和模塊化的目的。擴大應用范圍，向復合加工方向發(fā)展。
(3)不斷推進高能束流加工新技術(shù)、新工藝、新設(shè)備的工程化和產(chǎn)業(yè)化工作。
為實現(xiàn)以上發(fā)展目標，必須開展下列加工工藝的技術(shù)研究：
(1)激光加工技術(shù)
無再鑄層、無微裂紋渦輪葉片氣膜孔激光高效加工技術(shù)研究；
鋁合金、超強鋼、鈦合金、異種材料構(gòu)件以及大型空間曲面零件的激光焊接工藝研究，三維激光切割工藝規(guī)范及表面質(zhì)量控制技術(shù)和在線測量控制技術(shù)研究提高高溫合金、鋁合金等重要部件抗疲勞性能的激光沖擊技術(shù)研究；激光快速成型技術(shù)研究，大功率激光熔覆陶瓷涂層的工藝以及涂層組織結(jié)構(gòu)和性能的研究。
(2)電子束加工技術(shù)
150kV、15kW高壓電子槍及高壓電源的技術(shù)研究；
電子束物理氣相沉積技術(shù)的研究；
大厚度變截面鈦合金的電子束焊接技術(shù)研究及質(zhì)量評定；
典型復合材料飛機構(gòu)件的電子束固化工藝研究及其工程化研究；
多功能電子束加工技術(shù)研究。
(3)離子束和等離子體加工技術(shù)
復雜零件“保形”離子注入與混合沉積技術(shù)研究，獲得高密度等離子體方法研究；空間結(jié)構(gòu)焊接工藝參數(shù)自適應控制及焊縫自動跟蹤系統(tǒng)研究，以及等離子弧焊過程中變形控制技術(shù)研究；等離子噴涂陶瓷熱障涂層結(jié)構(gòu)、工藝及工程化研究；層流湍流自動轉(zhuǎn)換技術(shù)及軸向送粉、三維噴涂技術(shù)研究；層流等離子體噴涂系統(tǒng)的研制及其噴涂技術(shù)的研究。
(4)電加工技術(shù)
高品質(zhì)深小孔電液束加工技術(shù)研究；
高效、優(yōu)質(zhì)照相電解加工群孔技術(shù)研究；
多軸、多通道電火花加工群孔、異形孔技術(shù)研究；
大容量(5000A及以上)精密電解加工技術(shù)研究；
電解—電火花復合加工技術(shù)研究。
研究上述技術(shù)的關(guān)鍵在于：提高高能束流的品質(zhì)；開展特種加工過程的自動控制及計算機建模、仿真技術(shù)的研究；新材料加工特性研究；特種加工設(shè)備的研究等。