面向熔射制模的直接快遞制造耐高溫原型技術(shù)基礎(chǔ)研究
發(fā)布時間：2018-11-08 06:56
【摘要】：多品種、小批量、快速化的制造發(fā)展趨勢要求企業(yè)必須快速響應(yīng)市場和用戶的需求變化,隨著快速制模技術(shù)的不斷深入及其在工業(yè)領(lǐng)域尤其在在汽車行業(yè)中的廣泛應(yīng)用,要求進一步大幅度提高模具制造效率,降低成本。本文針對等離子熔射制模技術(shù)中的耐高溫原型制造問題,提出直接快速銑削粘土類耐高溫復(fù)合材料原型,減少原工藝中的復(fù)雜繁冗,以及翻制過程中的精度丟失。為此,以粘土類耐高溫原型為研究對象,以傳統(tǒng)銑削加工技術(shù)為理論支撐,從粘土類材料的設(shè)計、材料的干燥、材料的加工性能及其加工工藝參數(shù)等出發(fā),設(shè)計了粘土-莫來石耐高溫原型復(fù)合材料,系統(tǒng)地研究了粘土類陶瓷材料在加工過程中的相關(guān)基礎(chǔ)理論、方法及關(guān)鍵技術(shù)。 本文的主要研究內(nèi)容和創(chuàng)新性成果如下： 1.分析了快速制模技術(shù)發(fā)展現(xiàn)狀及存在的問題,針對等離子熔射制模技術(shù)中耐高溫原型通過硅膠模翻制的工藝,工藝復(fù)雜并且原型在翻制過程中精度容易丟失的問題,創(chuàng)新性的提出了面向等離子熔射制模的直接快速制造耐高溫原型工藝,有效簡化了工藝流程。 2.分析了陶瓷材料的加工技術(shù)現(xiàn)狀,創(chuàng)新性地提出未焙燒粘土材料的直接加工工藝。針對未焙燒粘土質(zhì)地軟、切屑粘刀、不易裝夾等問題,本文采用干燥處理,通過干燥實驗和理論分析制定了合理的干燥制度,實驗證明干燥后粘土類陶瓷材料強度提高,適合在機床裝夾及切屑不粘刀；進行了粘土材料的可加工性研究,分析了粘土原型的表面質(zhì)量、銑削力大小與加工參數(shù)的關(guān)系,同時進行了材料的培燒工藝及收縮特性的研究。 3.針對純粘土材料的抗熱震性差及培燒后收縮變形大等問題,本文進一步采用粘土莫來石復(fù)合材料制作耐高溫原型的工藝,研究以聚乙烯醇為粘結(jié)劑的耐高溫復(fù)合材料的粘結(jié)機理。通過改變粘土材料、耐火材料莫來石的配比以及含水量,研究上述兩個參數(shù)對材料抗彎強度以及培燒收縮性的影響。結(jié)果表明：隨著莫來石及水的含量的增加,材料干燥后抗彎強度降低；確定合理的含水量后,莫來石含量增加,焙燒后收縮減小,最終確定了耐高溫復(fù)合材料中合理的莫來石含量及含水量。 4.對于制備的耐高溫原型復(fù)合材料進行了可加工性研究,提出以彎曲強度(如3所述),切屑形態(tài)以及表面質(zhì)量來評價材料的可加工性。切屑形狀呈細長條狀,受加工參數(shù)的影響不大。在研究了主軸轉(zhuǎn)速、進給速度和軸向切削深度等加工參數(shù)對干燥后耐高溫原型表面粗糙度的影響基礎(chǔ)上,通過正交實驗運用二次回歸方法,建立了針對干燥后耐高溫原型加工參數(shù)的優(yōu)化數(shù)學(xué)模型；通過Matlab軟件運用遺傳算法求解出了降低原型表面粗糙度的最優(yōu)加工參數(shù),為干燥后耐高溫原型的加工質(zhì)量提供了可靠保障。
[Abstract]:The development trend of multi-variety, small batch and rapid manufacturing requires enterprises to respond to the changes of market and customer demand quickly. With the development of rapid mould making technology and its wide application in the field of industry, especially in automobile industry, Requirements to further greatly improve the efficiency of mold manufacturing, reduce costs. In this paper, aiming at the problem of high temperature resistance prototyping in plasma spray molding technology, a direct rapid milling of clay composite material prototype is proposed to reduce the complexity of the original process and the loss of precision in the turning process. Therefore, taking the clay prototype of high temperature resistance as the research object, taking the traditional milling technology as the theoretical support, starting from the design of the clay material, the drying of the material, the processing performance of the material and its processing technological parameters, etc. A prototype composite of clay-mullite high temperature resistance was designed, and the basic theories, methods and key technologies of clay ceramic materials in the process of processing were systematically studied. The main research contents and innovative results are as follows: 1. This paper analyzes the present situation and existing problems of rapid mold making technology. Aiming at the technology of high temperature resistance prototype turning through silicon gel mold in plasma spray molding technology, the process is complicated and the precision of prototype is easily lost in the process of turning. A direct rapid prototyping process of high temperature resistance for plasma spray molding is proposed, which simplifies the process effectively. 2. The present situation of ceramic material processing technology is analyzed, and the direct processing technology of uncalcined clay material is put forward innovatively. Aiming at the problems of soft texture of unroasted clay, chip sticking knife and difficult clamping, a reasonable drying system was established by drying experiment and theoretical analysis. It was proved that the strength of clay ceramic material increased after drying. Suitable for machine tool clamping and chip non-stick knife; The machinability of clay material was studied, and the relationship between the surface quality, milling force and processing parameters of the clay prototype was analyzed, and the sintering process and shrinkage characteristics of the material were also studied. 3. Aiming at the problems of poor thermal shock resistance of pure clay materials and large shrinkage and deformation after firing, this paper further uses clay mullite composite materials to fabricate high temperature resistance prototypes. The bonding mechanism of high temperature resistant composites with polyvinyl alcohol as binder was studied. By changing the ratio of clay material, refractory mullite and water content, the effects of the above two parameters on the bending strength and sintering shrinkage of the material were studied. The results show that the flexural strength decreases with the increase of mullite and water content. The mullite content increases and the shrinkage decreases after calcination when the reasonable moisture content is determined. Finally, the reasonable mullite content and water content in the high temperature resistant composite are determined. 4. The machinability of high temperature resistant prototype composites was studied. The machinability of the composites was evaluated by bending strength (as described in 3), chip morphology and surface quality. The shape of chip is long and thin, which is not affected by processing parameters. On the basis of studying the effect of machining parameters such as spindle speed, feed speed and axial cutting depth on the surface roughness of high temperature resistant prototype after drying, the quadratic regression method was used through orthogonal experiment. The optimization mathematical model for the processing parameters of the drying high temperature tolerance prototype was established. The optimal machining parameters for reducing the surface roughness of the prototype were obtained by using genetic algorithm with Matlab software, which provided a reliable guarantee for the processing quality of the prototype after drying.
【學(xué)位授予單位】：華中科技大學(xué)
【學(xué)位級別】：博士
【學(xué)位授予年份】：2013
【分類號】：TG76;TH16
本文編號：2317711
[Abstract]:The development trend of multi-variety, small batch and rapid manufacturing requires enterprises to respond to the changes of market and customer demand quickly. With the development of rapid mould making technology and its wide application in the field of industry, especially in automobile industry, Requirements to further greatly improve the efficiency of mold manufacturing, reduce costs. In this paper, aiming at the problem of high temperature resistance prototyping in plasma spray molding technology, a direct rapid milling of clay composite material prototype is proposed to reduce the complexity of the original process and the loss of precision in the turning process. Therefore, taking the clay prototype of high temperature resistance as the research object, taking the traditional milling technology as the theoretical support, starting from the design of the clay material, the drying of the material, the processing performance of the material and its processing technological parameters, etc. A prototype composite of clay-mullite high temperature resistance was designed, and the basic theories, methods and key technologies of clay ceramic materials in the process of processing were systematically studied. The main research contents and innovative results are as follows: 1. This paper analyzes the present situation and existing problems of rapid mold making technology. Aiming at the technology of high temperature resistance prototype turning through silicon gel mold in plasma spray molding technology, the process is complicated and the precision of prototype is easily lost in the process of turning. A direct rapid prototyping process of high temperature resistance for plasma spray molding is proposed, which simplifies the process effectively. 2. The present situation of ceramic material processing technology is analyzed, and the direct processing technology of uncalcined clay material is put forward innovatively. Aiming at the problems of soft texture of unroasted clay, chip sticking knife and difficult clamping, a reasonable drying system was established by drying experiment and theoretical analysis. It was proved that the strength of clay ceramic material increased after drying. Suitable for machine tool clamping and chip non-stick knife; The machinability of clay material was studied, and the relationship between the surface quality, milling force and processing parameters of the clay prototype was analyzed, and the sintering process and shrinkage characteristics of the material were also studied. 3. Aiming at the problems of poor thermal shock resistance of pure clay materials and large shrinkage and deformation after firing, this paper further uses clay mullite composite materials to fabricate high temperature resistance prototypes. The bonding mechanism of high temperature resistant composites with polyvinyl alcohol as binder was studied. By changing the ratio of clay material, refractory mullite and water content, the effects of the above two parameters on the bending strength and sintering shrinkage of the material were studied. The results show that the flexural strength decreases with the increase of mullite and water content. The mullite content increases and the shrinkage decreases after calcination when the reasonable moisture content is determined. Finally, the reasonable mullite content and water content in the high temperature resistant composite are determined. 4. The machinability of high temperature resistant prototype composites was studied. The machinability of the composites was evaluated by bending strength (as described in 3), chip morphology and surface quality. The shape of chip is long and thin, which is not affected by processing parameters. On the basis of studying the effect of machining parameters such as spindle speed, feed speed and axial cutting depth on the surface roughness of high temperature resistant prototype after drying, the quadratic regression method was used through orthogonal experiment. The optimization mathematical model for the processing parameters of the drying high temperature tolerance prototype was established. The optimal machining parameters for reducing the surface roughness of the prototype were obtained by using genetic algorithm with Matlab software, which provided a reliable guarantee for the processing quality of the prototype after drying.
【學(xué)位授予單位】：華中科技大學(xué)
【學(xué)位級別】：博士
【學(xué)位授予年份】：2013
【分類號】：TG76;TH16
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