A low-damage and high-efficiency processing method for an array composite pipe component

Abstract

The application relates to a low-damage high-efficiency processing method of an array composite pipe component and relates to the technical field of composite material honeycomb processing. The application simplifies the processing procedure of the end face of the array composite pipe into the processing procedure of a single composite pipe under different offset distances; a rectangular coordinate system is established with the axis of the composite pipe as the origin, the composite pipe is fixed, the grinding wheel moves in a linear feed motion along the X direction, the distance between the center of the grinding wheel and the center of the composite pipe along the Y direction is the offset distance; the maximum undeformed thickness of the grinding wheel in the cutting-in stage is calculated after the maximum undeformed thickness changes under different offset distances; the grinding wheel first keeps a larger offset ratio to complete the cutting-in process of the array composite pipe component in the positive direction of the X direction; after the grinding wheel feeds along the array composite pipe component in the Y direction by a certain distance, the grinding wheel moves in a linear feed motion along the negative direction of the X direction of the array composite pipe component to complete the removal of the remaining material of the single pipe until the removal is completed. The application has the advantages of good universality, strong programmability and high reliability.

Description

Technical Field

[0001] This invention relates to the field of composite material cellular processing technology, and more particularly to a low-damage, high-efficiency processing method for arrayed composite tube components. Background Technology

[0002] Arrayed composite tube components are made by bonding several composite tube cells together in a special arrangement on a horizontal plane, forming a novel thin-walled porous honeycomb structure. Arrayed composite tubes possess advantages such as low density, low coefficient of thermal expansion, high axial stiffness, and excellent impact resistance. They are typically bonded to composite skins to form composite honeycomb sandwich components, which have been applied in the aerospace field. Due to manufacturing limitations, arrayed composite tubes require further machining after molding to achieve complex surface shapes for assembly with the skin. Currently, using electroplated diamond cup-shaped grinding wheels to remove surface material from arrayed composite tubes is the mainstream processing method. Figure 1 As shown. However, the anisotropy and heterogeneity of composite materials, along with the thin walls and discontinuities of honeycomb components, pose significant challenges to the surface processing quality of arrayed composite tubes. In particular, numerous tearing damages occur on the processed surface during the end-face machining of the arrayed composite tubes, and these tearing damages are systematically formed within the machining area where the electroplated diamond cup-shaped grinding wheel cuts into the composite tube, such as... Figure 2 As shown, numerous periodically distributed tear damages severely affect the overall performance of the component.

[0003] To address the aforementioned technical challenges, this invention proposes a composite tube grinding geometry model and a low-damage end-face machining method for arrayed composite tube components. This aims to meet the needs of arrayed composite tube components in the field of composite material cellular processing, where theoretical contact is lacking and damage is difficult to suppress. Summary of the Invention

[0004] Based on the aforementioned technical problems, this invention, based on the structural characteristics of array composite tubes and the undeformed chip thickness model during the grinding wheel infeed stage, adopts a grinding method for the end face of array composite tubes with a large offset ratio and variable feed rate, specifically providing a low-damage and high-efficiency machining method for array composite tube components.

[0005] The technical means employed in this invention are as follows:

[0006] A low-damage, high-efficiency machining method for arrayed composite tube components includes the following steps: Before machining, a grinding geometry model of the arrayed composite tube is constructed, considering a simplified grinding wheel motion model and an undeformed chip thickness model during the grinding wheel infeed phase, taking into account the structural characteristics of the arrayed composite tube.

[0007] S1. The processing of the end face of the array composite tube is simplified into a processing process for a single composite tube at different offset distances.

[0008] S2. Establish a rectangular coordinate system Y with the axis of the composite tube as the origin. W O W X W The composite tube is fixed, and the grinding wheel makes a linear feed motion along the X direction. The distance between the center of the grinding wheel and the center of the composite tube along the Y direction is the offset distance δ.

[0009] S3. Based on the assumption of a single abrasive grain's circular motion trajectory, the thickness of the undeformed chip during the grinding wheel's entry stage is formed by the trajectories of two consecutive abrasive grains. Let the distance between the two consecutive abrasive grains be L. cut The linear velocity of the grinding wheel is v s The grinding wheel feed speed is v f The undeformed chip thickness Δx = v along the direction of the grinding wheel's velocity is obtained. f (L cut / v s );

[0010] S4. Under different offset distances, the maximum undeformed chip thickness varies continuously. The maximum undeformed thickness during the grinding wheel infeed stage is... Where θ represents the angle between the direction of the line connecting the axes of the grinding wheel and the composite tube and the direction of the feed speed, and e is the axis distance during the cutting stage;

[0011] S5. Consider the center distance e during the cutting stage as the initial center distance when the grinding wheel is tangent to the pipe wall, i.e., e = r s +r w +h, define the ratio of offset distance to initial axis distance as offset ratio α, and simplify the maximum undeformed chip thickness during the cutting phase to...

[0012] Furthermore, S1 is based on the premise that the cells of the arrayed composite tube are uniformly arranged in the X direction and staggered and tangentially arranged in the Y direction.

[0013] Furthermore, S3 assumes that the deformation of the pipe wall under grinding force is not considered.

[0014] Furthermore, the processing procedure includes the following steps:

[0015] S6. Based on the established model, the grinding wheel initially maintains a large offset ratio, and the feed rate is v. f1 The composite tube component moves in a straight line along the positive X direction to complete the cutting process into the composite tube.

[0016] S7. The grinding wheel is fed a certain distance along the Y direction of the array composite tube component. This distance is required to ensure that the grinding wheel and the composite tube are not tangent or that the theoretical tangent point is located in the processed area, so as to avoid the cutting stage during the processing.

[0017] S8, with feed rate v f2The linear feed motion along the negative X direction of the array composite tube component completes the removal of the remaining material in the single tube;

[0018] S9. Repeat steps S6, S7, and S8 to complete the processing of the end face of the array composite tube.

[0019] Furthermore, in S6, the initial bias ratio of the grinding wheel is greater than 0.5.

[0020] Furthermore, v f2 The value is v f1 At least 1.5 times.

[0021] Furthermore, in step S9, the speed of the final tool pass is v. f3 It satisfies 0.5V f3 ≥v f2 .

[0022] Compared with the prior art, the present invention has the following advantages: the processing method of the present invention is not only applicable to the processing of porous structure end faces and stepped surfaces, but also has universality for porous structures with different tubular cell sizes. The appropriate grinding wheel size can be quickly selected for porous components with different tubular cell sizes by means of the offset ratio; the method reduces the number of tearing damages caused by array composite tubes by rationally planning the tool path; the use of variable feed rate greatly improves the processing efficiency of array composite tube components, and the relationship between feed rates at different processing stages is given; the method has the advantages of good universality, strong programmability, and high reliability. Attached Figure Description

[0023] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0024] Figure 1 Schematic diagram of the processing of the end face of the array composite tube

[0025] Figure 2 Schematic diagram of tear damage distribution on the surface of the array composite tube

[0026] Figure 3 Schematic diagram of the geometric model for composite tube processing

[0027] Figure 4 Schematic diagram of the undeformed chip thickness model during the cutting phase.

[0028] Figure 5 A comparative diagram of low-damage end-face processing methods for array composite tubes

[0029] Figure 6 A comparative schematic diagram of the machining morphology of the end face of the array composite tube.

[0030] Figure 7 Schematic diagram of tear damage at the end face of array composite tube

[0031] In the diagram: 1. Grinding wheel, 2. Arrayed composite tube component, 3. Composite tube. Detailed Implementation

[0032] It should be noted that, unless otherwise specified, the embodiments and features described in the present invention can be combined with each other. The present invention will now be described in detail with reference to the accompanying drawings and embodiments.

[0033] To make the objectives, technical solutions, and advantages of the embodiments of the present invention clearer, the technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. The following description of at least one exemplary embodiment is merely illustrative and is in no way intended to limit the present invention or its application or use. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0034] It should be noted that the terminology used herein is for the purpose of describing particular embodiments only and is not intended to limit the scope of exemplary embodiments according to the invention. As used herein, the singular form is intended to include the plural form as well, unless the context clearly indicates otherwise. Furthermore, it should be understood that when the terms "comprising" and / or "including" are used in this specification, they indicate the presence of features, steps, operations, devices, components, and / or combinations thereof.

[0035] Unless otherwise specifically stated, the relative arrangement, numerical expressions, and values ​​of the components and steps described in these embodiments do not limit the scope of the invention. It should also be understood that, for ease of description, the dimensions of the various parts shown in the drawings are not drawn to actual scale. Techniques, methods, and devices known to those skilled in the art may not be discussed in detail, but where appropriate, such techniques, methods, and devices should be considered part of the specification. In all examples shown and discussed herein, any specific values ​​should be interpreted as merely exemplary and not as limitations. Therefore, other examples of exemplary embodiments may have different values. It should be noted that similar reference numerals and letters in the following figures denote similar items; therefore, once an item is defined in one figure, it need not be further discussed in subsequent figures.

[0036] In the description of this invention, it should be understood that the orientation or positional relationship indicated by directional terms such as "front, back, up, down, left, right", "horizontal, vertical, horizontal" and "top, bottom" is generally based on the orientation or positional relationship shown in the accompanying drawings, and is only for the convenience of describing this invention and simplifying the description. Unless otherwise stated, these directional terms do not indicate or imply that the device or element referred to must have a specific orientation or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation on the scope of protection of this invention. The directional terms "inner" and "outer" refer to the inner and outer contours relative to the outline of each component itself.

[0037] For ease of description, spatial relative terms such as "above," "over," "on the upper surface of," "above," etc., are used herein to describe the spatial positional relationship of a device or feature as shown in the figures to other devices or features. It should be understood that spatial relative terms are intended to encompass different orientations in use or operation besides the orientation of the device as described in the figures. For example, if the device in the figures is inverted, a device described as "above" or "above" other devices or structures would subsequently be positioned as "below" or "under" other devices or structures. Thus, the exemplary term "above" can include both "above" and "below." The device may also be positioned in other different ways (rotated 90 degrees or in other orientations), and the spatial relative descriptions used herein will be interpreted accordingly.

[0038] Furthermore, it should be noted that the use of terms such as "first" and "second" to define components is merely for the purpose of distinguishing the corresponding components. Unless otherwise stated, the above terms have no special meaning and therefore should not be construed as limiting the scope of protection of this invention.

[0039] This invention discloses a low-damage, high-efficiency processing method for arrayed composite tube components;

[0040] Before machining, a grinding geometry model for the array composite tube is constructed, considering the simplified grinding wheel motion model and the undeformed chip thickness model during the grinding wheel infeed stage, taking into account the structural characteristics of the array composite tube. The steps include:

[0041] like Figure 1 As shown, S1, considering the characteristics of the cells of the array composite tube 2 being uniformly arranged in the X direction and staggered and tangentially arranged in the Y direction, the processing process of the end face of the array composite tube is simplified to the processing process of a single composite tube 3 along different offset distances.

[0042] S2, such as Figure 3 As shown, a rectangular coordinate system Y is established with the axis of the composite tube as the origin. W O W XW The composite tube is fixed, and the grinding wheel 1 makes a linear feed motion along the X direction. The distance between the center of the grinding wheel and the center of the composite tube along the Y direction is the offset distance δ.

[0043] S3, such as Figure 4 As shown, neglecting the deformation of the pipe wall under grinding force, based on the assumption of a circular motion trajectory of a single abrasive grain, the thickness of the undeformed chip during the grinding wheel infeed stage is formed by the trajectories of two consecutive abrasive grains. Let the distance between the two consecutive abrasive grains be L. cut The linear velocity of the grinding wheel is v s The grinding wheel feed speed is v f The thickness of the undeformed chip along the direction of the grinding wheel's velocity is Δx = v f (L cut / v s );

[0044] S4. Under different offset distances, the maximum undeformed chip thickness varies continuously, according to... Figure 4 The geometric relationship shown indicates that the maximum undeformed part during the grinding wheel cutting stage is...

[0045] S5. Due to the small wall thickness, the center distance e does not change much during the cutting stage. Therefore, e can be considered as the initial center distance when the grinding wheel is tangent to the wall, i.e., e = r. s +r w +h, define the ratio of offset distance to initial axis distance as offset ratio α, and the maximum undeformed chip thickness during the cutting phase can be simplified as

[0046] The processing procedure is carried out according to the following steps:

[0047] S6. Based on the model established in S5, under the condition that other machining parameters remain unchanged, increasing the offset ratio can reduce the maximum undeformed chip thickness during the infeed stage. Therefore, the grinding wheel can initially maintain a relatively large offset ratio (greater than 0.5), and the feed rate is v. f1 The composite tube component moves in a straight line along the positive X direction to complete the cutting process into the composite tube.

[0048] S7, such as Figure 5 As shown in method B, the grinding wheel is fed a certain distance along the Y direction of the array composite tube component. This distance needs to ensure that the grinding wheel and the composite tube are not tangent or that the theoretical tangent point is located in the processed area, so as to avoid the cutting stage during the processing.

[0049] S8. Then, the composite tube component is fed linearly along the negative X direction at a feed rate to remove the remaining material from the single tube. In this embodiment, v f2 Generally it is v f1 Twice as much;

[0050] S9. Repeat the methods described in S6, S7, and S8 above to complete the processing of the end face of the array composite tube;

[0051] Example 1

[0052] The specific implementation steps for establishing composite pipes are as follows:

[0053] S1, such as Figure 3 As shown, a coordinate system Y is established with the axis of the composite tube as the origin. W O W X W The inner diameter of the composite pipe is r w The thickness is h, and the grinding wheel moves in a straight line along the X direction with a certain offset distance. Let the radius of the grinding wheel be r. s Axis O S Coordinates can be represented as (x s Let the center distance of the cutting-in stage be e;

[0054] S2, such as Figure 4 As shown, the abrasive grain trajectory is simplified to a circular trajectory, and the distance between two consecutive abrasive grains is denoted as L. cut The maximum undeformed chip thickness formed by the two abrasive grain trajectories is Δx = v f (L cut / v s The linear velocity of the grinding wheel is v. s The grinding wheel feed speed is v f , ;

[0055] S3. Based on geometric relationships, the maximum undeformed chip thickness during the actual cutting stage can be expressed as the distance between C and E. Since Δx is much smaller than the grinding wheel radius r... s Then |CD| is approximately equal to Δx, and according to geometric relations, we can obtain |CE|=|CD|cosθ;

[0056] S4, Here cosθ can be expressed as Since the pipe wall thickness is small, the center distance e changes little during the cutting stage. Therefore, e can be considered as the initial center distance when the grinding wheel is tangent to the pipe wall, i.e., e = r. s +r w +h, unify the grinding wheel size and composite tube size, and define the ratio of offset distance to initial axis distance as offset ratio α;

[0057] S5, the maximum undeformed chip thickness during the cutting phase can be simplified to: Under the condition of a fixed abrasive grain size, the maximum undeformed chip thickness during the infeed stage is affected by the feed rate, grinding speed, and offset ratio.

[0058] The specific implementation steps of the low-damage end face processing method for arrayed composite tube components are as follows:

[0059] S6, such as Figure 5 As shown, considering the characteristics of composite tubes being uniformly arranged in the X direction and staggered and tangentially arranged in the Y direction, two methods for processing the end faces of arrayed composite tubes are described.

[0060] As a comparative example, S7, such as Figure 5 As described in method A, the grinding wheel, with an offset ratio of 0, performs a reciprocating linear feed motion along the X direction of the array composite tube at a low feed rate vf1.

[0061] S8. The spacing between toolpaths is the distance along the Y direction between the centers of adjacent pipes. Each pass of the tool can complete the cutting of a row of composite tubes, ensuring high processing efficiency;

[0062] S9, such as Figure 5 As described in method B, the grinding wheel first moves in a straight line along the positive X direction of the arrayed composite tube at a large feed rate vf2 when the offset ratio is greater than 0.5, thus realizing the cutting process of the composite tube. Under the condition of a large offset ratio, the thickness of the undeformed chip during the cutting stage can be reduced, and tearing damage can be suppressed;

[0063] S10. Then, the grinding wheel feeds a certain distance along the Y direction and moves in a straight line in the opposite X direction at a higher feed speed vf3, gradually removing the residual material from the composite tube. It is worth noting that in this path, it is necessary to ensure that the tangent point between the grinding wheel and the composite tube is located in the processed area, or in other words, to ensure that the grinding wheel and the composite tube are not tangent, so as to avoid the occurrence of a secondary cutting process.

[0064] S11. Then repeat steps S9 and S10 to grind the next row of composite tubes. For the last pass, since the grinding wheel will not cut into the adjacent tubes, a higher feed rate vf3 is still used for the last pass.

[0065] S13, the above feed rate relationship is 1.5v f1 ≤v f2 ≤0.5v f3 ;

[0066] S14, such as Figure 6 As shown, by comparing the processing morphology of the array composite tube end face obtained by the two processing methods, the processing surface quality obtained by the array composite tube end face processing method with large offset ratio and variable feed rate is higher.

[0067] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention, and not to limit them; although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some or all of the technical features; and these modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the scope of the technical solutions of the embodiments of the present invention.

Claims

1. A low-damage, high-efficiency processing method for arrayed composite tube components, characterized in that, Before machining, a grinding geometry model for the array composite tube is constructed, considering the simplified grinding wheel motion model and the undeformed chip thickness model during the grinding wheel infeed stage, taking into account the structural characteristics of the array composite tube. The steps include: S1. The processing of the end face of the array composite tube is simplified into a processing process for a single composite tube at different offset distances. S2. Establish a rectangular coordinate system with the axis of the composite tube as the origin. Y W O W X W The composite tube remains stationary, while the grinding wheel makes a linear feed motion along the X direction. The distance between the center of the grinding wheel and the center of the composite tube along the Y direction is the offset distance. δ ; S3. Based on the assumption of a single abrasive grain's circular motion trajectory, the thickness of the undeformed chip during the grinding wheel's entry stage is formed by the trajectories of two consecutive abrasive grains. Let the distance between the two consecutive abrasive grains be denoted as... L cut The linear velocity of the grinding wheel is v s The grinding wheel feed speed is v f To obtain the undeformed chip thickness along the direction of the grinding wheel's movement speed. ; S4. Under different offset distances, the maximum undeformed chip thickness changes continuously, and the maximum undeformed chip thickness during the grinding wheel infeed phase... h m for: ,in, θ This indicates the angle between the direction of the line connecting the axes of the grinding wheel and the composite tube and the direction of the feed speed. e This refers to the center distance of the cutting phase. S5, adjust the center distance of the cutting phase. e Consider this as the initial axis distance when the grinding wheel is tangent to the pipe wall. ,in r s Where is the radius of the grinding wheel. r w The inner diameter of the composite pipe. h For the pipe wall thickness, the ratio of the offset distance to the initial axis distance is defined as the offset ratio. α The maximum undeformed chip thickness during the cutting phase is simplified to .

2. The method according to claim 1, characterized in that, S1 is based on the fact that the cells of the arrayed composite tube are uniformly arranged in the X direction and staggered and tangentially arranged in the Y direction.

3. The method according to claim 1, characterized in that, S3 assumes that the deformation of the pipe wall under grinding force is not considered.

4. The method according to any one of claims 1-3, characterized in that, The processing procedure includes the following steps: S6. Based on the established model, the grinding wheel initially maintains a large offset ratio, and the feed rate is... v f1 The composite tube component moves in a straight line along the positive X direction to complete the cutting process into the composite tube. S7. The grinding wheel is fed a certain distance along the Y direction of the array composite tube component. This distance is required to ensure that the grinding wheel and the composite tube are not tangent or that the theoretical tangent point is located in the processed area, so as to avoid the cutting stage during the processing. S8, at feed rate v f2 The linear feed motion along the negative X direction of the array composite tube component completes the removal of the remaining material in the single tube; S9. Repeat steps S6, S7, and S8 to complete the processing of the end face of the array composite tube.

5. In the method according to claim 4, in S6, the initial bias ratio of the grinding wheel is greater than 0.

5.

6. The method according to claim 4, v f2 The value is v f1 At least 1.5 times.

7. According to the method of claim 4, in step S9, the speed of the last feed is... v f3 It satisfies 0.5 v f3 ≥ v f2 .

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