The research and application of special processing technology
Abstract: This paper discusses the emergence and development of special processing technology, and rapid prototyping processing, ultrasonic processing, electron beam and ion beam processing and laser processing to expand the elaboration of the process principle of the various processing methods and specific applications in production practice. Finally, the development direction of special processing technology for the outlook.
Keywords: special machining; rapid prototyping technology; ultrasonic machining; electron beam and ion beam machining; laser machining
1. The emergence and development of special machining technology
Machining, as a long history of machining methods, has played a great role in promoting the material civilization of mankind and production activities. For the industrial sector, the designed parts or machines must rely on processing methods to realize, if there is no effective processing methods, even the best design ideas can not be converted into products. For example, in the 18th century 70's someone invented the steam engine, but due to the production equipment at that time do not have a high degree of precision and with the requirements of the steam engine cylinder, so has not been able to produce a steam engine can work properly [1]. Until the emergence of the cylinder boring machine, only to solve this production problem, so that the steam engine has been widely used, causing the first industrial revolution. Therefore, we can find that the machining method for the realization of design ideas and socio-economic development plays a major role in how.
With the development of production and the need for scientific experiments, the requirements for products are getting higher and higher, the future of technical products to high precision, high speed, heavy load, high temperature and high pressure, miniaturization and high reliability and other directions, in order to achieve these new requirements, it is necessary to use the new materials and new structures, so the machinery manufacturing sector has also put forward a lot of new requirements. Special processing is in this strong social demand for the emergence and development, and it has a better than traditional machining characteristics and further promote its research and application, so far, special machining technology has been a lot of kinds of machining precision and productivity is also higher and higher. It can be said that special machining technology has become an essential processing method in the modern machinery manufacturing industry.
The traditional mechanical processing of metal processing using mechanical energy and cutting force, while the special processing mainly use electrical energy, chemical energy, light energy, acoustic energy and thermal energy and other energy to remove the metal, so the special machining technology can be used to process a variety of high hardness, high strength, high brittleness and high toughness of the metal or non-metallic materials. Because of the special processing using a wide range of tools, such as laser, ultrasonic, electron beam and ion beam, so easy to realize the full automation of the processing process, which has a very important significance for the organization and management of modern production.
Since 1943, when Mr. and Mrs. Boris Lazarinko of the former Soviet Union began to study the phenomenon of spark discharge corrosion of switching contacts, special machining technology has undergone more than sixty years of development. Currently, many specialty machining methods have been developed, such as EDM, EDM wire cutting, electrochemical machining and laser machining. Now, people have also studied the theory of special machining applied to the traditional machining methods in the composite processing methods, such as vibratory cutting and vibratory milling. As special machining technology is particularly suitable for difficult-to-machine materials, complex surfaces and precision micro-fabricated surface machining, so special machining has a great applicability and development potential in the tooling, molds, gauges, instruments, spacecraft and microelectronic components and other manufacturing in an increasingly wide range of applications. In the future, special machining will be to improve processing accuracy and surface quality, improve productivity and automation, the development of composite processing and ultra-precision machining and other directions.
2. Rapid Prototyping Technology
Rapid Prototyping (RP) is an additive processing method, mainly used to manufacture prototype parts, so that the design of new products can be quickly evaluated, modified and functional experiments, can be greater to shorten the product development cycle. Rapid prototyping technology combines mechanical engineering, CAD, CNC technology, laser technology and materials science and technology in one, easy to realize the automation of the production process, and efficient and convenient, so this prototype manufacturing process is increasingly used in production practice. In accordance with the rapid prototyping technology using materials and process principles, can be divided into four types: photosensitive resin liquid-phase curing molding method (SL), selective laser powder sintering molding (SLS), sheet layered overlay molding (LOM), fused filament deposition molding (FDM).
3. Ultrasonic processing technology
Frequency of more than 16000Hz sound waves called ultrasound, it is a longitudinal wave, capable of transmitting very strong energy, and when it is propagated through the liquid medium, it will produce hydraulic shock phenomenon. Ultrasonic machining technology (USM) using the end face of the tool for ultrasonic frequency vibration, through the abrasive suspension so that the abrasive particles in the ultrasonic vibration under the action of mechanical impact, abrasive action, as well as ultrasonic cavitation to process brittle and hard materials. Due to the process principle and characteristics of ultrasonic processing technology, ultrasonic processing has many special applications. For example, the processing of deep small holes, wire drawing die and cavity mold grinding and polishing, the processing of difficult-to-machine materials, ultrasonic vibration cutting, ultrasonic electrolytic composite processing, ultrasonic EDM composite processing, ultrasonic cleaning, ultrasonic cutting and so on. Ultrasonic processing technology and the development of new materials are complementary, in the future, ultrasonic processing will certainly have more applications and development.
4. Electron Beam and Ion Beam Processing
Electron Beam Machining (EBM) using very high energy density of the electron beam, with very high speed impact on the surface of the workpiece, so that most of the kinetic energy into thermal energy, making the impact of the workpiece material localized melting and gasification, so as to achieve the goal of changing the physical and chemical properties of the surface of the processed workpiece material and the shape and size of the location. Electron beam processing device includes electron gun, vacuum system, control system and power supply, electron beam is made of tungsten or tantalum emission cathode in the heating state. Due to the process principle and characteristics of E-beam machining, EBM technology can be used to process shaped holes and special surfaces, etching, welding, heat treatment, and E-beam lithography.
Ion Beam Machining (IBM) utilizes the impact effect, sputtering effect, and injection effect that occurs when an ion beam with high energy is shot onto the surface of a material to perform different processes. Since the ion beam bombardment of the material is layer-by-layer removal of atoms, it is possible to achieve nanoscale machining accuracy. Ion beam processing can be categorized into three types according to their process principles and purposes: etching processing for removing material from the workpiece, plating processing for coating the surface of the workpiece, and ion implantation processing for surface modification. As the electron beam and ion beam is easy to realize the precise control, so you can realize the full automation of the process, but the focus of the electron beam and ion beam, deflection and other aspects of the many technical problems remain to be solved.
5. Laser processing
Laser technology began in the 1960s, can be used for punching, cutting, welding, heat treatment and laser storage. Laser production from the material of the stimulated radiation, that is, some of the substable energy level structure of the material, in a certain external photon energy excitation, the so-called particle beam inversion phenomenon, in the particle beam inversion of the state, if a beam of energy equal to the difference between the energy of the base state and the substable energy of the photon irradiation of the material, will produce stimulated radiation, the output of a large amount of light energy. Because lasers are characterized by high intensity, good monochromaticity, good coherence and good directionality, they can be used to process almost any material. Currently commonly used lasers are solid-state lasers (ruby lasers, rubidium glass lasers and rubidium-doped yttrium aluminum garnet lasers) and gas lasers (carbon dioxide lasers and argon ion lasers), in production practice, the impact of the laser processing of the various factors need to be more in-depth study in order to more fully utilize laser processing technology.
6. Conclusion
In recent years, with the new materials, new structures, complex surface parts, special requirements of the growing demand for parts, special machining technology has been more and more widely used, in the future, with the further improvement of electromechanical control technology, special machining technology will be more automated, make full use of computer technology, which can make special machining toward automation and flexible direction. and flexible direction [2]. In the future, special machining technology will be increasingly used in precision microfabrication, composite processing and green processing.
References
[1] Jinchun Liu, Kicheng Bai, Yongfeng Guo. Special Machining [M], Beijing: Machinery Industry Press, 2011: 1-6.
[2]Wang J, Fan J, et al. New Progress of Special Machining Technology [J], Light Industry Machinery, 2008, 26(4): 5-7.
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