CN116727699A - Method for machining sharp corner stepped hole of laminated composite material component - Google Patents
Method for machining sharp corner stepped hole of laminated composite material component Download PDFInfo
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- CN116727699A CN116727699A CN202310845084.8A CN202310845084A CN116727699A CN 116727699 A CN116727699 A CN 116727699A CN 202310845084 A CN202310845084 A CN 202310845084A CN 116727699 A CN116727699 A CN 116727699A
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- 238000000034 method Methods 0.000 title claims abstract description 50
- 239000002131 composite material Substances 0.000 title claims abstract description 27
- 238000003754 machining Methods 0.000 title claims abstract description 25
- 238000005520 cutting process Methods 0.000 claims description 24
- 230000007547 defect Effects 0.000 abstract description 20
- 238000005336 cracking Methods 0.000 abstract description 9
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N Silicium dioxide Chemical compound O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 description 14
- 239000000377 silicon dioxide Substances 0.000 description 7
- 229920000049 Carbon (fiber) Polymers 0.000 description 6
- 239000004917 carbon fiber Substances 0.000 description 6
- 239000000835 fiber Substances 0.000 description 6
- VNWKTOKETHGBQD-UHFFFAOYSA-N methane Chemical compound C VNWKTOKETHGBQD-UHFFFAOYSA-N 0.000 description 6
- 238000004804 winding Methods 0.000 description 4
- 238000010586 diagram Methods 0.000 description 3
- 239000000047 product Substances 0.000 description 3
- 239000000463 material Substances 0.000 description 2
- 239000007921 spray Substances 0.000 description 2
- 241001669679 Eleotris Species 0.000 description 1
- 238000002679 ablation Methods 0.000 description 1
- 238000005299 abrasion Methods 0.000 description 1
- 230000001154 acute effect Effects 0.000 description 1
- 239000003822 epoxy resin Substances 0.000 description 1
- 239000012467 final product Substances 0.000 description 1
- 238000009413 insulation Methods 0.000 description 1
- 239000011159 matrix material Substances 0.000 description 1
- 239000002245 particle Substances 0.000 description 1
- -1 phenolic aldehyde Chemical class 0.000 description 1
- 229920000647 polyepoxide Polymers 0.000 description 1
- 238000003825 pressing Methods 0.000 description 1
- 230000002265 prevention Effects 0.000 description 1
- 239000012779 reinforcing material Substances 0.000 description 1
Classifications
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23B—TURNING; BORING
- B23B1/00—Methods for turning or working essentially requiring the use of turning-machines; Use of auxiliary equipment in connection with such methods
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- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Turning (AREA)
Abstract
The application discloses a method for processing a sharp-angle stepped hole of a laminated composite material member, which comprises the following steps: on a lathe, clamping a small end of a workpiece by using a first chuck, turning the outer shape of a large end of the workpiece to form a straight line section with a fixed outer diameter, and machining a clamping reference section of the large end of the workpiece; the second chuck is adopted to clamp a clamping reference section of the large end of the workpiece, the end face of the small end of the workpiece is firstly turned to form a smooth surface, then an inner through hole of the small end of the workpiece is turned, the inner through hole reaches a first through hole diameter, and a straight line section of the inner through hole is intersected with an intersecting line of an inner cone profile of the workpiece to form a P1 point; pushing out a step surface by 1-2 mm based on the point P1 to enable a step hole at the step surface to be reamed to a first aperture, wherein the hole depth reaches the first hole depth; and (3) processing the point P1 serving as a reference to form a sharp corner, reaming the stepped hole to a second aperture, and enabling the hole depth to reach the second hole depth. The application effectively avoids the defects of chipping, cracking and the like, and has high processing efficiency and strong feasibility.
Description
Technical Field
The application belongs to the technical field of composite material machining, and relates to a method for machining a sharp-angle stepped hole of a laminated composite material component.
Background
The composite material member has the excellent characteristics of light weight, high strength, ablation resistance and the like, the reinforcing material is generally carbon fiber or high silica fiber, the matrix material is generally phenolic aldehyde or epoxy resin, and the composite material is widely used in the aerospace field. At present, composite materials are widely adopted for preparing parts on an engine spray pipe assembly of an aerospace vehicle, such as throat lining, backing, expansion section and other structures, the structural parts mainly play roles in heat prevention and heat insulation, the appearance is a revolving body structure, and the structure is generally prepared by adopting a mould pressing or winding process. After the composite member is formed, a turning process is required to remove allowance to ensure the wall thickness size and shape requirements of the member. The composite material belongs to a difficult-to-process material, a fiber body in the composite material is used as a hard particle continuous abrasion cutter, the cutter is extremely easy to wear, the structure is also easy to have defects such as layering, cracking, burrs and the like, and particularly for a complex special structure, various defects are more easy to occur in the machining process.
The expansion section is an important component of an engine spray pipe assembly of the aerospace craft, the structure is a laminated structure formed by winding two composite prepregs of carbon fibers and high silica fibers, the inside is of a carbon fiber structure, the outside is of a high silica fiber structure, and the inner shape of a workpiece presents cone characteristics. The expansion section is formed by adopting turning to form a product structure after being wound and formed into a revolving body, the small end of the cone body is provided with a stepped hole feature, the stepped hole is provided with a sharp corner unique shape with a fixed inner diameter, and the key is how to effectively process the sharp corner stepped hole feature meeting the size requirement without generating defects such as chipping and cracking.
Disclosure of Invention
In order to effectively solve the problems in the prior art, the application aims to provide a method for processing a sharp-angle stepped hole of a laminated composite material component.
In order to achieve the above purpose, the present application adopts the following technical scheme:
a method for processing a sharp corner stepped hole of a laminated composite material member comprises the following steps:
s1, clamping a small end of a workpiece by using a first chuck on a lathe, turning a straight line section with a fixed outer diameter on the outer shape of a large end of the workpiece, and machining a clamping reference section of the large end of the workpiece;
s2, clamping a clamping reference section of the large end of the workpiece by adopting a second chuck, turning the end face of the small end of the workpiece to form a smooth surface, turning an inner through hole of the small end of the workpiece, enabling the inner through hole to reach a first through hole diameter, and intersecting a straight line section of the inner through hole with an intersecting line of an inner cone profile of the workpiece to form a P1 point;
s3, pushing out a step surface by 1-2 mm based on the point P1 to enable a stepped hole at the step surface to be reamed to a first aperture, wherein the hole depth reaches the first hole depth;
s4, processing the point P1 as a reference to form a sharp corner, reaming the stepped hole to a second aperture, and enabling the hole depth to reach the second hole depth;
s5, continuously turning the inner through hole to a second through hole diameter, wherein the straight line section of the inner through hole is intersected with the intersecting line of the inner cone profile to form a point P;
s6, pushing out a 1mm machined step surface by taking the point P as a reference, so that the inner diameter of the stepped hole reaches a third aperture, and the hole depth reaches a third hole depth;
and S7, turning the end surface of the step by taking the point P as a reference to form a sharp corner of the stepped hole, wherein the hole depth reaches the fourth hole depth.
In the preferred mode, in the step S1, the first chuck is a four-jaw chuck, and the alignment is performed on the small end area, the middle area and the large end area of the inner profile of the workpiece by using the dial indicator, so that the roundness runout of the three areas is ensured to be controlled within 0.2mm.
In the preferred mode, in the step S2, the second chuck is a three-jaw self-centering chuck, the inner through hole of the small end of the workpiece is turned step by step, the inner diameter of the inner through hole is gradually increased in the turning process, and the inner diameter of the small end of the workpiece forms a straight line segment.
In a preferred manner, in the step S3, during turning, turning blades are turned layer by layer from inside to outside, and the cutting amount of each layer is controlled to be 0.5mm.
Preferably, in the step S6, turning the turning tool piece layer by layer from inside to outside, and controlling the cutting amount of each layer to be 0.5mm.
In a preferred mode, in the step S7, three layers of turning are performed during processing, the cutting tool size of two layers is 0.4mm, and the cutting tool size of the last cutting tool is 0.2mm.
The workpiece blank is of a laminated structure, the inside of the workpiece blank is of a structure formed by winding carbon fiber materials, the inner wall and the outer wall of the workpiece blank are of conical characteristics, a straight line section is arranged at the small end of a cone, and the inner surface is not turned after being formed and is directly used as the inner surface of a final product; the high silica fiber is continuously wound outside the carbon fiber structure body, so that a structure with uneven thickness is formed, the outer molded surface of the blank also has the characteristic of a conical structure, the small end is provided with a straight line section, the wall thickness value is larger, and the large end is provided with no straight line section. The inner surface of the blank is not required to be processed, the outer surface is mainly processed, particularly, the small end is provided with a stepped hole, the stepped hole is provided with sharp corner characteristics, namely, the inner circumference of the end surface of the product is provided with a sharp edge with a fixed inner diameter. How to form the sharp angle is very critical, not only the specified inner diameter size is required, but also the whole circumference is ensured to be in sharp angle and not to have straight line segments, and the defects of chipping, cracking and the like are avoided.
First, when machining a small-end stepped hole of a workpiece, a large end must be used as a clamping position. The large end of the blank piece is not provided with a straight line section, and cannot be directly clamped, and a clamping reference surface needs to be machined first. It should be noted that the small end of the workpiece has a requirement for processing a sharp-angle stepped hole, and the inner profile of the stepped hole of the workpiece is required to form a strict sharp angle along the circumferential direction, so that a straight line segment cannot exist in a local area. Therefore, the clamping of the large end of the workpiece and the alignment of the workpiece are very important, and the center line of the workpiece is kept consistent with the axis of the lathe spindle after the clamping of the large end, otherwise, a step Kong Jianjiao meeting the requirement cannot be formed.
On the lathe, the small end is clamped by a chuck, and a large end clamping reference is processed. The positioning of the large-end clamping reference is very critical, and if the eccentricity exists, the defect of straight line segments is very easy to occur when the small-end stepped hole is machined. The straight line section of the inner surface of the small end is too short to clamp, so that the straight line section of the outer surface of the small end of the blank is clamped by adopting a four-jaw chuck. The four-jaw chuck is selected instead of the three-jaw self-centering chuck, because the four-jaw clamping can conveniently adjust the pose of the workpiece, and the center line of the workpiece is ensured to be consistent with the axis of the main shaft of the machine tool. And (3) aligning the inner molded surface of the large end by adopting a dial indicator, namely keeping the axis of the inner molded surface of the workpiece consistent with the axis of the main shaft of the machine tool. Because the axes of the large end and the small end of the inner molded surface of the blank are possibly eccentric, the small end area, the middle area and the large end area of the inner molded surface are respectively aligned, so that the roundness runout of the three areas is controlled within 0.2mm. Turning a cutter on the end face of the large end to form a smooth surface, and turning the outer shape of the large end to form a straight line segment with a fixed outer diameter, wherein the straight line segment is used as a clamping reference for the next processing.
There are internal diameter size requirements at the sharp angle of the small-end stepped hole, and difficulties exist in meeting the internal diameter size requirements and the sharp angle in the circumferential direction at the same time. The biggest problem is how to formulate a reference point P at the sharp corner, which must guarantee the inside diameter size requirement. The application firstly processes the inner through hole to enable the inner through hole to reach the design size requirement, at the moment, the inner through hole presents a straight line segment, and from the two-dimensional section, the outline straight line of the inner through hole and the outline intersecting line of the conical inner molded surface form an intersection point automatically, and the intersection point is a datum point.
The specific implementation process is as follows: and clamping the reference section processed by the outer surface of the large end by adopting a three-jaw chuck, and turning a cutter to form a smooth surface on the end surface of the small end. And then gradually turning the inner through hole of the small end in a plurality of steps, wherein the inner diameter of the inner through hole is gradually increased in the turning process, at the moment, the inner diameter of the small end forms a straight line section, and the inner through hole and the intersecting line of the inner cone profile form a datum point.
Finally, after the datum point is found, machining allowance and turning sequence can be formulated, and important references are provided for subsequent machining of the stepped hole meeting the requirements.
If sharp corners are directly machined in one step, defects of chipping and cracking are easy to occur, and how to avoid the machining defects is important. Two reference points P1 and P points are made, the P1 point being the intermediate process reference point and the P point being the final reference point. The middle P1 datum point is formulated to process the sharp angle of the stepped hole at the P1 point, so that most of the allowance can be removed, whether the chipping defect exists can be observed, and if the chipping exists, the turning process can be further adjusted to prevent the defect.
The step Kong Jian angle at the machining P1 point is divided into two steps, and the step surface is machined in advance in the first step, so that most of machining allowance is removed firstly, and the situation that the cutting force is overlarge to cause chipping at the sharp angle due to overlarge allowance in the subsequent step hole machining is prevented; and secondly, processing the sharp corner feature at the point P1, so as to verify whether the defects such as the chipping and the straight line section occur in the local area along the circumferential direction, and if the defects exist, the pose of the workpiece and the turning process can be adjusted, and the subsequent point P processing is not influenced.
The specific implementation process is as follows: and (3) taking the point P1 as a reference, pushing out by 1-2 mm to process the step surface, so that the inner diameter and the hole depth of the step hole at the step surface reach a certain size. When in turning, the turning tool pieces are turned layer by layer from inside to outside, because the cutting angle of the turning tool pieces and the machined surface of the workpiece form an acute angle so as to prevent the chipping, and the cutting amount of each layer is controlled to be 0.5mm. And then the point P1 is used as a reference for processing to form a sharp angle, and the stepped hole is equally reamed to a specified size at the moment, and the hole depth also reaches a preset size. At this time, attention is paid to observing whether a sharp corner at the point P1 has a chipping, checking whether a sharp corner in the circumferential direction has a straight line segment, and analyzing the cause that may occur.
Finally, a step Kong Jianjiao meeting the requirements is machined with reference to point P. The inner through hole is turned to reach the final size by a multi-step method, and at the moment, the straight line section of the inner through hole is intersected with the intersecting line of the inner cone profile to form a P point. Then, the step surface is processed by pushing out 1mm based on the point P, so that the inner diameter of the stepped hole reaches the final size, and the hole depth reaches the specified size. When in turning, the turning tool pieces are turned layer by layer from inside to outside, and the cutting amount of each layer is controlled to be 0.5mm. And after checking for defects, turning the end face of the step by taking the point P as a reference to form a sharp corner of the stepped hole, wherein the depth of the hole reaches the final size. Three layers of turning are carried out during processing, the cutting rate of two layers is 0.4mm respectively, and the cutting rate of the last cutting tool is 0.2mm.
The processing difficulty of sharp angle shoulder hole lies in: firstly, a datum point is difficult to find for processing, so that the processing requirements of strictly forming sharp corners along the circumferential direction and not generating defects of local straight line segments and ensuring the dimensional accuracy of the inner diameter are not guaranteed; secondly, a reasonable processing flow is difficult to form, and the problem of how to distribute the processing allowance exists; thirdly, defects such as chipping and cracking are easy to generate during sharp corner processing.
The application provides a turning process method aiming at the problems of turning a stepped hole and forming a sharp angle of a high silica and carbon fiber laminated composite material: the method provides a reasonable workpiece clamping method, and meets the workpiece alignment requirement; providing a method for forming a datum point by processing an intersecting line of the inner through hole and the inner molded surface, and providing a reference for determining the size of the processed stepped hole and distributing allowance; the method for processing the stepped hole in stages is provided, wherein the stepped hole is processed in advance by taking the middle point as a reference, and most of the allowance is removed to prevent processing defects; and (3) turning layer by layer and strictly controlling the cutting amount of each layer, and finally processing to form the sharp-angle stepped hole. In actual processing, the method can rapidly process the stepped hole to form a sharp corner shape required by design, avoid the occurrence of straight line segments and greatly reduce the defects of chipping, cracking and the like. The method forms a reasonable turning process flow and can be used for rapid machining of similar structures.
The application has the following advantages:
the sharp-angle stepped hole structure meeting the technical size requirement can be efficiently processed by combining the structural characteristics of the workpiece and the processing requirements, so that the defects of chipping, cracking and the like are effectively avoided, the processing efficiency is high, and the feasibility is high. The method can be widely used for machining composite material workpieces with similar sharp-angle stepped hole structures, and reduces the risks of defects such as chipping and cracking.
Drawings
FIG. 1 is a schematic diagram of a workpiece and a blank;
FIG. 2-schematic drawing of the workpiece and blank dimensions;
FIG. 3-blank tip grip schematic;
FIG. 4-schematic view of the alignment position of the inner profile;
FIG. 5 is a schematic diagram of a machining reference of the large end outer surface of the blank;
FIG. 6-P1 is a schematic view of a reference pre-machined step surface;
FIG. 7-P1 is a schematic diagram of reference stepped hole processing;
FIG. 8-P is a schematic view of a reference preform step surface;
fig. 9-P reference stepped hole processing completion schematic.
Wherein: 1-blank, 2-workpiece product, 3-step hole, 4-sharp angle feature, 5-high silica fiber composite layer, 6-carbon fiber composite layer, 7-four jaw chuck, 8-external surface standard, 9-P1 step surface feature, 10-P step surface feature.
Detailed Description
The present application will be described in detail with reference to the accompanying drawings.
The present application will be described in further detail with reference to the drawings and examples, in order to make the objects, technical solutions and advantages of the present application more apparent. It should be understood that the specific embodiments described herein are for purposes of illustration only and are not intended to limit the scope of the application.
Examples:
the blank 1 is a revolution body structure, the length of a small-end straight line segment is 5mm, and the inner diameter of the straight line segment is phi 99.6mm. The blank is prepared by adopting a winding process and comprises two composite material laminated structures, wherein the inner layer is a carbon fiber composite material layer 6, the outer layer is a high silica composite material layer 5, and the inner surface of the inner layer is formed and is not machined. The small end profile of the workpiece 2 is mainly characterized in that a stepped hole 3 is machined, a sharp angle 4 is formed at the stepped hole, a point P is formed by intersecting a hole profile line on the section with an intersecting line of the conical inner profile, and the angle degree at the point P is 75.2 degrees. The inner diameter of the P point is phi 104mm, the depth of the stepped hole is 10mm, and the inner diameter is phi 140mm. The machining requirement is that sharp angles are formed at the P point, the requirement of the inner diameter of the P point is met, the defect of broken blocks cannot be caused, and the local area cannot be allowed to have straight line segments on the circumference.
The processing process flow is as follows:
(1) On a sleeper lathe, the small end outer surface of a workpiece 2 is clamped by a four-jaw hard jaw chuck 7, and then the small end area, the middle area and the large end area of the inner surface are respectively aligned by using a dial indicator, so that the alignment aims to continuously adjust the pose of the workpiece and ensure that roundness runout of the three areas is controlled within 0.2mm.
(2) And turning and finishing the end face of the large end, and processing the outer molded surface to form a straight line segment, wherein the outer diameter reaches phi 232mm, and the straight line segment is used as a clamping reference 8 for the next processing.
(3) And clamping the reference section processed by the outer surface of the large end by adopting a three-jaw self-centering chuck, and turning and finishing the end surface of the small end. Turning the inner through hole of the small end in three steps, wherein the inner diameter is changed into: Φ100→Φ102→Φ103. At this time, the inner surface of the small end forms a straight line segment, and the straight line of the inner through hole intersects with the intersecting line of the inner cone surface to form a P1 point.
(4) And turning the stepped hole on the basis of the phi 103 inner hole so as to reduce the allowance of a workpiece and prevent excessive allowance from causing excessive cutting force during the subsequent stepped hole machining so as to cause chipping. And (3) taking the point P1 as a reference, pushing out 2mm to process the step surface 9, so that the inner diameter of the step hole reaches phi 138, and the hole depth is 9mm. When in turning, the turning tool pieces are turned layer by layer from inside to outside, and the cutting amount of each layer is controlled to be 0.5mm.
(5) And (3) processing the point P1 as a reference to form a sharp angle, reaming the stepped hole to phi 139, enabling the hole depth to reach 8.9mm, observing whether the sharp angle at the point P1 has a collapse block and a straight line segment, and analyzing possible reasons.
(6) Continuously turning the inner through hole in two steps, wherein the inner diameter is changed into: phi 103.5-phi 104, at this time, the straight line section of the inner through hole intersects with the intersecting line of the inner cone profile to form a P point.
(7) And (3) taking the point P as a reference, pushing out 1mm to process the step surface 10, so that the inner diameter of the stepped hole reaches phi 140, and the hole depth is 9mm. When in turning, the turning tool pieces are turned layer by layer from inside to outside, and the cutting amount of each layer is controlled to be 0.5mm.
Turning the end face of the step by taking the point P as a reference to form a sharp corner, wherein the depth of the stepped hole reaches 10mm. Three layers of turning are carried out during processing, the cutting rate of two layers is 0.4mm respectively, and the cutting rate of the last cutting tool is 0.2mm.
The application is not limited to the specific embodiments described above. The application extends to any novel one, or any novel combination, of the features disclosed in this specification, as well as to any novel one, or any novel combination, of the steps of the method or process disclosed.
Claims (6)
1. A method for processing a sharp-angle stepped hole of a laminated composite material member is characterized by comprising the following steps:
s1, clamping a small end of a workpiece by using a first chuck on a lathe, turning a straight line section with a fixed outer diameter on the outer shape of a large end of the workpiece, and machining a clamping reference section of the large end of the workpiece;
s2, clamping a clamping reference section of the large end of the workpiece by adopting a second chuck, turning the end face of the small end of the workpiece to form a smooth surface, turning an inner through hole of the small end of the workpiece, enabling the inner through hole to reach a first through hole diameter, and intersecting a straight line section of the inner through hole with an intersecting line of an inner cone profile of the workpiece to form a P1 point;
s3, pushing out a step surface by 1-2 mm based on the point P1 to enable a stepped hole at the step surface to be reamed to a first aperture, wherein the hole depth reaches the first hole depth;
s4, processing the point P1 as a reference to form a sharp corner, reaming the stepped hole to a second aperture, and enabling the hole depth to reach the second hole depth;
s5, continuously turning the inner through hole to a second through hole diameter, wherein the straight line section of the inner through hole is intersected with the intersecting line of the inner cone profile to form a point P;
s6, pushing out a 1mm machined step surface by taking the point P as a reference, so that the inner diameter of the stepped hole reaches a third aperture, and the hole depth reaches a third hole depth;
and S7, turning the end surface of the step by taking the point P as a reference to form a sharp corner of the stepped hole, wherein the hole depth reaches the fourth hole depth.
2. The method for machining the sharp-corner stepped hole of the laminated composite material member according to claim 1, wherein the method comprises the following steps of: in the step S1, the first chuck is a four-jaw chuck, and the alignment is performed on the small end area, the middle area and the large end area of the inner molded surface of the workpiece by using a dial indicator, so that the roundness runout of the three areas is controlled within 0.2mm.
3. The method for machining the sharp-corner stepped hole of the laminated composite material member according to claim 1, wherein the method comprises the following steps of: in the step S2, the second chuck is a three-jaw self-centering chuck, an inner through hole at the small end of the workpiece is turned step by step, the inner diameter of the inner through hole is gradually increased in the turning process, and the inner diameter of the small end of the workpiece forms a straight line segment.
4. The method for machining the sharp-corner stepped hole of the laminated composite material member according to claim 1, wherein the method comprises the following steps of: in the step S3, turning the turning tool piece layer by layer from inside to outside during turning, and controlling the cutting amount of each layer to be 0.5mm.
5. The method for machining the sharp-corner stepped hole of the laminated composite material member according to claim 1, wherein the method comprises the following steps of: in the step S6, turning the turning tool piece layer by layer from inside to outside during turning, and controlling the cutting amount of each layer to be 0.5mm.
6. The method for machining the sharp-corner stepped hole of the laminated composite material member according to claim 1, wherein the method comprises the following steps of: in the step S7, three layers of turning are carried out during processing, the cutting amount of two layers is 0.4mm respectively, and the cutting amount of the last cutting tool is 0.2mm.
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