CN113000952A - Method for processing novel trapezoidal thread of C/SiC ceramic matrix composite material - Google Patents
Method for processing novel trapezoidal thread of C/SiC ceramic matrix composite material Download PDFInfo
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- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23G—THREAD CUTTING; WORKING OF SCREWS, BOLT HEADS, OR NUTS, IN CONJUNCTION THEREWITH
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Abstract
The invention relates to a method for processing novel trapezoidal threads of a C/SiC ceramic matrix composite. (1) Designing an integral type variable-diameter diamond round nose milling cutter and an electroplated diamond thread milling cutter by taking the tooth form of the trapezoidal thread as a standard; (2) processing the large diameter of the trapezoidal thread by using the integral type reducing diamond round nose milling cutter designed in the step (1); (3) roughly machining the thread by using the electroplated diamond thread milling cutter designed in the step (1) according to a thread instantaneous center-free envelope machining process and a tool path design method with variable feed rate and variable cutting depth; (4) and (3) utilizing the electroplated diamond thread milling cutter designed in the step (1) to finish the thread according to a transient-center-free envelope machining process.
Description
Technical Field
The invention relates to a structural design and processing method of a novel trapezoidal thread, in particular to a structural design and high-precision low-damage processing technology of a novel trapezoidal thread of a C/SiC ceramic matrix composite material with high hardness, large brittleness, non-homogeneity and anisotropy, and belongs to the field of precision machining of composite materials.
Background
In recent years, the C/SiC ceramic matrix composite material reinforced by a 2D or 3D fiber braided or woven structure is widely applied to the field of aerospace due to the excellent characteristics of good integrity, strong designability, high temperature resistance, damage resistance and the like.
With the wide application and development of the C/SiC ceramic matrix composite threaded connection structural member, the C/SiC ceramic matrix composite connection technology, especially the C/SiC ceramic matrix composite threaded fastening technology, becomes one of the key technologies for manufacturing the large-scale member with high reliability. Compared with metal materials, the C/SiC ceramic matrix composite connecting piece has excellent thermophysical properties, can keep better rigidity and strength in a high-temperature oxidation environment, and can be better matched with structural parts made of the same materials.
However, the C/SiC ceramic matrix composite material brings great challenges to the processing technology due to its high hardness, large brittleness, anisotropy, non-homogeneity and poor thermal conductivity, and the difficulties such as cutting force, tool life and tool reliability need to be comprehensively considered during processing. The common thread structure has small tooth structure size, low thread strength and unique anisotropy of materials, so that processing damage such as thread breakage, tooth form ultra-poor and the like which cannot be repaired is easily generated in the thread processing process, and the high reliability and long service life of high-end aerospace equipment bring quality risk and potential safety hazard.
Disclosure of Invention
The invention aims to creatively design a novel thread structure, adopts a trapezoidal thread structure with higher strength, better rigidity and strong wear resistance to replace a common thread, and provides a high-precision and low-damage processing cutter and a processing method of the novel trapezoidal thread structure of the anisotropic C/SiC ceramic matrix composite material based on a non-instant envelope processing technology.
The above purpose of the invention is mainly realized by the following technical scheme: a processing method of novel trapezoidal threads of C/SiC ceramic matrix composite materials comprises the following steps:
(1) designing an integral type variable-diameter diamond round nose milling cutter and an electroplated diamond thread milling cutter by taking the tooth form of the trapezoidal thread as a standard; the cutter bar substrate of the integral reducing diamond round nose milling cutter adopts nano tungsten carbide-cobalt hard alloy, and the cutting edge material adopts artificial polycrystalline diamond; the matrix of the electroplated diamond thread milling cutter is nano tungsten carbide-cobalt hard alloy, an electroplated layer is made of nickel manganese cobalt alloy, the structure is a thread profiling structure, the surface of the electroplated layer of the milling cutter is electroplated with 250-300 meshes of carborundum with the concentration of 110-120%;
(2) processing the large diameter of the trapezoidal thread by using the integral type reducing diamond round nose milling cutter designed in the step (1);
(3) roughly machining the thread by using the electroplated diamond thread milling cutter designed in the step (1) according to a thread instantaneous center-free envelope machining process and a tool path design method with variable feed rate and variable cutting depth;
the cutter path design method with variable feed rate and variable cutting depth divides the whole rough machining process into three stages of rough machining cutting, allowance removal cutting and thread forming cutting, wherein the feed amount in the rough machining stage is 1200-2000 mm/min, the cutting depth is 0.08-0.12 mm, and the number of layers of the formed spiral cutter path is 8-16. The feeding amount of the allowance removing stage is 1200-1600 r/min, the cutting depth is 0.05-0.08 mm, and the number of layers of the formed spiral cutter path is 4-8. The feeding amount in the thread forming stage is 800-1200 mm/min, the cutting depth is 0.01-0.05 mm, and the number of layers of the formed spiral cutter path is 2-4;
(4) and (3) utilizing the electroplated diamond thread milling cutter designed in the step (1) to finish the thread according to a transient-center-free envelope machining process.
Preferably, the trapezoidal thread is a metric trapezoidal thread, the tooth form angle of the trapezoidal thread is 30 degrees, and the tooth form section of the trapezoidal thread is an isosceles trapezoid.
Preferably, the section of the tool of the electroplated diamond thread milling cutter is isosceles trapezoid, the length of a cutting edge is 0.469-0.964 mm, the diameter of a tool shank is phi 10-phi 14mm, the diameter of a thread tool is phi 20-phi 30mm, the truncated clamping angle A of the tool is more than or equal to 25 degrees and less than 30 degrees, and the round angle R of a tool tip is less than or equal to 0.13 mm.
Preferably, the tool cutoff angle is preferably 28 ° to 29.6 °.
Preferably, the electroplated diamond thread milling cutter is suitable for a dry cutting process in a non-cooled state.
Preferably, the cutter bar diameter phi of the integral type reducing diamond round nose milling cutter is 9-9.8mm, the cutting edge diameter phi is 10mm, the cutter point fillet R is half of the gap of the trapezoidal thread crest, and the cutter parameters are executed according to negative tolerance; the number of blades is 2.
Preferably, the thread is machined to a large diameter d1 in the step (2), and d1 is d-Td/2; wherein d is the nominal diameter of the thread; td is the thread major diameter tolerance.
Preferably, the processing parameters of the trapezoidal thread instantaneous center-free envelope processing technology in the step (3) are as follows: the inner tolerance and the outer tolerance of the interpolation are both 0.005mm, the rotating speed of the main shaft is 4500-5000 r/min, and the cutting mode is forward milling.
Preferably, the parameters of the thread instantaneous center-free envelope finish machining in the step (4) are as follows: the interpolation inner tolerance and the interpolation outer tolerance are 0.001mm, the rotating speed of the main shaft is 5000-8000 r/min, and the cutting mode is straight milling.
Preferably, the number of the thread profiling layer descending type cutting tool paths in the processing process of the step (4) is 2-4, the feeding amount is 500-800 mm/min, the cutting depth is 0.01mm, and the compensation value of a single cutter is less than or equal to 0.02 mm.
Compared with the prior art, the invention has the following beneficial effects:
(1) the invention designs a novel trapezoidal thread connecting structure aiming at a C/SiC ceramic matrix composite threaded connecting structural member, and compared with common threads, the novel trapezoidal thread connecting structure has the advantages of strong connecting tightness, difficulty in loosening, good manufacturability, high tooth root strength, strong wear resistance and the like.
(2) Aiming at the problems of thread damage, tooth form super-difference and the like in the process of machining threads of C/SiC ceramic matrix composite materials with high hardness, large brittleness, heterogeneity and anisotropy, the invention designs and prepares the special machining cutter with high precision and low damage by comprehensively considering factors such as interference of a spiral rising angle, contact arc length, tooth socket expansion amount, cutter preparation process, cutter diameter and rigidity, cutter structural form and the like through the principle interference analysis of a trapezoidal thread and the machining cutter. The cutting performance and the service life of the prepared cutter are improved, the cutter has excellent cutting matching property with the non-homogeneous C/SiC ceramic matrix composite, and the effects of cost reduction and efficiency improvement are achieved.
(3) The invention designs a processing technology without instant envelope, creatively adopts a processing cutter path with variable feed and variable cutting depth, and improves the processing efficiency of mass production on the premise of not reducing the tooth form retention rate of the screw teeth. The retention rate of the trapezoidal thread profile processed by the process is more than or equal to 95 percent, and the processing time of a single thread is less than or equal to 22 min.
(4) Aiming at the requirements of high strength, high precision and high wear resistance of a C/SiC ceramic matrix composite threaded connection structural member in the aerospace field, the invention provides a novel trapezoidal thread structure of a C/SiC ceramic matrix composite, and designs a novel trapezoidal thread processing cutter and a processing method of a heterogeneous C/SiC ceramic matrix composite with high product yield aiming at the structure. By the technology, the tightness, the product quality and the processing efficiency of the novel trapezoidal threads of the C/SiC ceramic matrix composite material are greatly improved, and the requirement for high-quality production and manufacturing of products in the aerospace field is met.
Drawings
FIG. 1 shows a trapezoidal thread structure of a C/SiC ceramic matrix composite material designed based on three-dimensional design software.
FIG. 2 is a simulation of the machining motion of the novel trapezoidal thread special machining tool for the C/SiC ceramic matrix composite.
FIG. 3 is a non-instantaneous center enveloping processing technique for novel trapezoidal threads of C/SiC ceramic matrix composites;
FIG. 4 is a schematic view of an electroplated diamond thread milling cutter;
FIGS. 5 to 7 show the corresponding design parameter dimensions of three types of trapezoidal threads, Tr8-1.5, Tr10-2 and Tr12-3, respectively, machined by the electroplated diamond thread milling cutter; (design parameters are theoretical values and actual final tool parameters are increased manufacturing tolerances)
FIG. 8 is a schematic view of the thread after machining;
fig. 9 is a schematic structural view of the integral reducing diamond round nose milling cutter.
Detailed Description
The present invention will be described in detail with reference to the accompanying drawings.
The invention aims at the difficult processing characteristics of high hardness, high wear resistance, non-homogeneous and anisotropic C/SiC ceramic matrix composite material threads, such as easy breaking of screw threads, easy out-of-tolerance of thread shapes, low tooth root strength and the like. Firstly, designing a trapezoidal thread pair structure based on the characteristics of thicker pitch diameter, good tooth profile strength, high tooth root strength, excellent centering performance, excellent manufacturability and the like of a trapezoidal thread compared with a common 60-degree thread; secondly, designing and preparing a novel special diamond cutter for processing the trapezoidal threads of the C/SiC ceramic matrix composite material based on the principle interference analysis of the trapezoidal threads and a processing cutter and comprehensively considering factors such as the interference of a spiral rising angle, the length of a contact arc, the expansion amount of a tooth socket, the category and the concentration of diamond raw materials, the preparation process of the cutter, the diameter and the rigidity of the cutter, the structural form of the cutter and the like; and finally, processing the trapezoidal thread based on a non-instantaneous-center envelope processing technology of the trapezoidal thread and based on a three-axis numerical control processing interpolation principle. By the process method, the connecting thread structure has the advantages of strong strength and rigidity, good manufacturability, high wear resistance, thread retention rate and long service life of the diamond cutter special for processing. The method for designing and processing the novel trapezoidal thread structure of the C/SiC ceramic matrix composite comprises the following steps:
step (I): the trapezoidal thread structure and the diamond cutter special for cutting and processing are designed according to the processing precision of common threads by taking the trapezoidal thread profile as a standard, and the diamond cutter comprises an integral reducing diamond round nose milling cutter and an electroplated diamond thread milling cutter.
The trapezoidal thread is a metric trapezoidal thread, the tooth form angle of the trapezoidal thread is 30 degrees, the tooth form section is an isosceles trapezoid, the thread rotation direction is right-handed, and the precision is 7 e/7H.
The designed integral reducing diamond round nose milling cutter structure is integral and reducing, the cutter bar substrate adopts nano tungsten carbide-cobalt hard alloy, the cutting edge material adopts artificial polycrystalline diamond (PCD), the cutting edge and the cutter bar adopt a high-frequency induction brazing process, the diameter B of the cutter bar is phi 9.8mm, the diameter D of the cutting edge is phi 10mm, the round corner R of the cutter point is 0.8mm, and the number of the cutter edges is 2, as shown in figure 9.
As shown in figure 4, the electroplated diamond thread milling cutter adopts diamond raw materials of metal bond artificial diamond, model MBD8, mesh number is 250-300 meshes, diamond concentration is 110-120%, a cutter base body is nano tungsten carbide-cobalt hard alloy, an electroplating layer adopts nickel manganese cobalt alloy, the diamond is electroplated on the surface of the electroplating layer, the structure is a thread profiling structure, the section of the cutter is isosceles trapezoid, the length L of the cutter is 80mm, the length U of a cutting edge is 0.469-0.964 mm, the diameter B of a cutter handle is phi 10-phi 14mm, the diameter D of a thread cutter is phi 20-phi 30mm, the section clamping angle A of the cutter is 25-29.6 degrees, and the fillet R is less than or equal to 0.13. The tool is suitable for dry cutting process in a non-cooling state.
The sizes of corresponding design parameters when the cutter is used for processing three types of trapezoidal threads Tr8-1.5, Tr10-2 and Tr12-3 are respectively shown in figures 5-7, and the sizes of the threads after being formed are shown in figure 8.
Step (II): and (3) machining the large diameter of the trapezoidal thread to d1 by using the integral reducing diamond round nose milling cutter designed in the step (I), wherein d1 is d-Td/2. Wherein d is the nominal diameter of the thread; td is the thread major diameter tolerance.
Step (three): and (3) roughly machining the thread by using the electroplated diamond thread milling cutter designed in the step (I) according to a thread instantaneous center-free envelope machining process and a tool path design method with variable feed rate and variable cutting depth.
The processing technology of the trapezoidal thread without instantaneous center envelope is shown in figure 1, and the main processing parameters are as follows: the inner tolerance and the outer tolerance of the interpolation are both 0.005mm, the rotating speed of the main shaft is 4500-5000 r/min, and the cutting mode is forward milling. Designing variable cutting parameters and a variable tool path, dividing the whole processing process into three stages of rough machining cutting, allowance removal cutting and thread forming cutting, wherein each stage adopts a thread profile layer descending type cutting tool path, the feed amount of the rough machining stage is 1200-2000 mm/min, the cutting depth is 0.08-0.12 mm, and the number of layers of the formed spiral tool path is 8-16. The feeding amount of the allowance removing stage is 1200-1600 r/min, the cutting depth is 0.05-0.08 mm, and the number of layers of the formed spiral cutter path is 4-8. The feed amount in the thread forming stage is 800-1200 mm/min, the cutting depth is 0.01-0.05 mm, and the number of layers of the formed spiral cutter path is 2-4.
Step (IV): and (5) utilizing the electroplated diamond thread milling cutter designed in the step (I) to finish the thread according to a non-instant-center enveloping machining process.
The parameters of the thread non-instantaneous-center envelope finish machining in the step (IV) are as follows: the interpolation inner tolerance and the interpolation outer tolerance are 0.001mm, the rotating speed of the main shaft is 5000-8000 r/min, and the cutting mode is straight milling. The number of layers of the designed thread profile-modeling layer descending type cutting tool path is 2-4, the feed amount is 500-800 mm/min, the cutting depth is 0.01mm, and the compensation value of a single cutter is less than or equal to 0.02 mm.
The invention is described in further detail below by means of specific examples:
examples
The processing object is an orthogonal three-dimensional C fiber C/SiC ceramic matrix composite Tr8 multiplied by 1.5-7e threaded connector, and the processing mode is copying dry cutting.
(1) The design of a metric trapezoidal thread structure with an angle of 30 degrees, a precision of 7e and a major diameter of 7eMinor diameter ofThe screw thread rotating direction is right-handed.
(2) Designing and preparing the integral diamond reducing round nose milling cutter and the electroplated diamond thread milling cutter. The integral diamond round nose milling cutter is integral in structure, the cutter bar substrate is made of nano tungsten carbide-cobalt hard alloy, the cutting edge is made of artificial polycrystalline diamond (PCD), the cutting edge and the cutter bar are made of a high-frequency induction brazing process, the diameter of the cutter bar is 9.75mm, the rotating diameter of the cutting edge is 10mm, the number of the cutting edges is 2, and the round angle R of the cutter point is 0.798 mm. The diamond raw material adopted by the electroplated diamond thread milling cutter is MBD8, the mesh number is 300 meshes, the diamond concentration is 115%, the cutter substrate is nano tungsten carbide-cobalt hard alloy, and the electroplated layer is nickel manganese cobalt alloy. The length of a cutting edge of the thread cutter is 0.468mm, the diameter of a cutter rod is phi 14mm, the diameter of the cutting edge is phi 30mm, the truncated included angle of the cutter is 29.6 degrees, and a cutter point fillet R is 0.05 mm.
(3) The integral reducing diamond round nose milling cutter is used for processing the thread with the major diameter of 7.925 mm.
(4) Roughly machining the trapezoidal thread by using an electroplated diamond thread milling cutter according to a non-instantaneous-center enveloping machining process, wherein the cutting parameters are as follows: the internal tolerance and the external tolerance of the interpolation are uniformly selected to be 0.005mm, the rotating speed of the main shaft is 4500r/min, and the cutting mode is forward milling. The number of the cutting paths in the rough machining cutting stage is 8, the feed rate is 1800mm/min, and the cutting depth is 0.1 mm. The number of the cutter paths in the allowance removing and cutting stage is 4, the feed rate is 1300mm/min, and the cutting depth is 0.05 mm. The number of the cutter paths in the thread forming stage is 3, the feed rate is 1000mm/min, and the cutting depth is 0.02 mm.
(5) And (3) finely machining the trapezoidal thread by using an electroplating diamond thread milling cutter according to a transient-center-free envelope machining process, wherein the cutting parameters are as follows: the inner tolerance and the outer tolerance of the interpolation are uniformly selected to be 0.001mm, the rotating speed of a main shaft is 5000mm/min, the number of cutter paths is 2, the feed rate is 800mm/min, the cutting depth is 0.02, the compensation value of a single cutter is 0.01mm, and the cutting mode is forward milling. After the thread is processed, the thread is detected to be qualified by using a Tr8 multiplied by 1.5-7e thread ring gauge.
The machining and inspection of the threads in the example show that the C/SiC ceramic matrix composite trapezoidal thread connecting piece (Tr8 multiplied by 1.5-7e) machined by the machining method has strong tooth root strength and rigidity, good process connectivity, tooth form retention rate of not less than 95%, product qualification rate of not less than 98%, and the average value of the service life of the cutter can reach 16 hours in dry cutting.
The invention has not been described in detail in part in the common general knowledge of a person skilled in the art.
Claims (10)
1. A processing method of novel trapezoidal threads of C/SiC ceramic matrix composite materials is characterized by comprising the following steps:
(1) designing an integral type variable-diameter diamond round nose milling cutter and an electroplated diamond thread milling cutter by taking the tooth form of the trapezoidal thread as a standard; the cutter bar substrate of the integral reducing diamond round nose milling cutter adopts nano tungsten carbide-cobalt hard alloy, and the cutting edge material adopts artificial polycrystalline diamond; the matrix of the electroplated diamond thread milling cutter is nano tungsten carbide-cobalt hard alloy, an electroplated layer is made of nickel manganese cobalt alloy, the structure is a thread profiling structure, the surface of the electroplated layer of the milling cutter is electroplated with 250-300 meshes of carborundum with the concentration of 110-120%;
(2) processing the large diameter of the trapezoidal thread by using the integral type reducing diamond round nose milling cutter designed in the step (1);
(3) roughly machining the thread by using the electroplated diamond thread milling cutter designed in the step (1) according to a thread instantaneous center-free envelope machining process and a tool path design method with variable feed rate and variable cutting depth;
the cutter path design method with variable feed rate and variable cutting depth divides the whole rough machining process into three stages of rough machining cutting, allowance removal cutting and thread forming cutting, wherein the feed amount in the rough machining stage is 1200-2000 mm/min, the cutting depth is 0.08-0.12 mm, and the number of layers of the formed spiral cutter path is 8-16. The feeding amount of the allowance removing stage is 1200-1600 r/min, the cutting depth is 0.05-0.08 mm, and the number of layers of the formed spiral cutter path is 4-8. The feeding amount in the thread forming stage is 800-1200 mm/min, the cutting depth is 0.01-0.05 mm, and the number of layers of the formed spiral cutter path is 2-4;
(4) and (3) utilizing the electroplated diamond thread milling cutter designed in the step (1) to finish the thread according to a transient-center-free envelope machining process.
2. The method of claim 1, wherein: the trapezoidal thread is a metric trapezoidal thread, the tooth form angle of the trapezoidal thread is 30 degrees, and the tooth form section is an isosceles trapezoid.
3. The method of claim 2, wherein: the cross section of the tool of the electroplated diamond thread milling cutter is isosceles trapezoid, the length of a cutting edge is 0.469-0.964 mm, the diameter of a tool shank is phi 10-phi 14mm, the diameter of a thread tool is phi 20-phi 30mm, the cutting-clamping angle A of the tool is more than or equal to 25 degrees and less than 30 degrees, and the fillet R of a tool nose is less than or equal to 0.13 mm.
4. The method of claim 3, wherein: the tool cutoff angle is preferably 28-29.6.
5. The method of claim 1, wherein: the electroplated diamond thread milling cutter is suitable for a dry cutting process in a non-cooling state.
6. The method of claim 2, wherein: the cutter bar diameter phi of the integral type reducing diamond round nose milling cutter is 9-9.8mm, the cutting edge diameter phi is 10mm, the cutter point fillet R is half of the gap of the trapezoidal thread crest, and the cutter parameters are executed according to negative tolerance; the number of blades is 2.
7. The method of claim 1, wherein: the diameter of the machined thread is increased to d1 in the step (2), and d1 is d-Td/2; wherein d is the nominal diameter of the thread; td is the thread major diameter tolerance.
8. The method of claim 1, wherein: the processing parameters of the trapezoidal thread instantaneous center-free envelope processing technology in the step (3) are as follows: the inner tolerance and the outer tolerance of the interpolation are both 0.005mm, the rotating speed of the main shaft is 4500-5000 r/min, and the cutting mode is forward milling.
9. The method of claim 1, wherein: the parameters of the thread non-instantaneous-center envelope finish machining in the step (4) are as follows: the interpolation inner tolerance and the interpolation outer tolerance are 0.001mm, the rotating speed of the main shaft is 5000-8000 r/min, and the cutting mode is straight milling.
10. The method of claim 9, wherein: in the processing process of the step (4), the number of the layers of the thread profiling layer descending type cutting tool path is 2-4, the feed rate is 500-800 mm/min, the cutting depth is 0.01mm, and the single-time cutter compensation value is less than or equal to 0.02 mm.
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Cited By (1)
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CN114833406A (en) * | 2022-03-24 | 2022-08-02 | 航天材料及工艺研究所 | Multi-blade grinding method for external threads of continuous fiber reinforced ceramic matrix composite |
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