A method and equipment for low-disturbance fabrication of long-span carbon fiber honeycomb components
By obtaining the relationship between cutting line tension and strain, and combining it with the side length of the regular polygonal structure of the carbon fiber honeycomb component, the cutting path and the extension of the electric push rod are set, and the cutting line tension is dynamically adjusted. This solves the problems of vibration and cantilever beam extrusion in the cutting process of large-size carbon fiber honeycomb components, and achieves high-precision, stable, and low-disturbance processing.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- DALIAN MARITIME UNIVERSITY
- Filing Date
- 2026-01-26
- Publication Date
- 2026-06-02
AI Technical Summary
Large-size carbon fiber honeycomb components are prone to problems such as cutting line vibration and cantilever beam compression during the cutting process, which can lead to unstable processing quality issues such as component tearing and edge collapse. In addition, traditional processing methods have the disadvantages of low precision and low efficiency.
By pre-observing the relationship between the tension and strain of the cutting line, and combining it with the side length of the regular polygonal structure of the carbon fiber honeycomb component, the cutting path and the elongation of the electric push rod are set, and the tension of the cutting line is dynamically adjusted. With the help of the partition plate and guide wheel adjustment mechanism, low-disturbance cutting is achieved.
It significantly reduces cutting line chatter and cantilever beam compression, improves cutting accuracy, avoids component tearing and edge collapse, enhances processing quality and stability, simplifies processing procedures, and improves efficiency.
Smart Images
Figure CN122125774A_ABST
Abstract
Description
Technical Field
[0001] This invention relates to the field of carbon fiber honeycomb component processing technology, and in particular to a low-disturbance processing method and equipment for long-span carbon fiber honeycomb components. Background Technology
[0002] Carbon fiber honeycomb components, due to their superior properties such as high specific strength, low density, high toughness, and corrosion resistance, have begun to replace traditional metal materials as a new type of load-bearing structural material. The development of modern large-size carbon fiber honeycomb components is influenced by their processing precision and surface forming quality; therefore, high-precision processing of large-size carbon fiber honeycomb components has always been a key focus in the field of large-size carbon fiber honeycomb component processing.
[0003] Carbon fiber honeycomb composites exhibit characteristics such as weak rigidity in the macroscopic honeycomb structure and hardness and brittleness in the microscopic carbon fiber material. During processing, the honeycomb material is prone to deformation under the pushing action of the cutting tool, while the hardness and brittleness of carbon fiber result in a weak ability to withstand deformation. The significant difference between structural characteristics and material properties leads to extremely complex material removal mechanical behavior and macroscopic / microscopic morphological evolution of damage. Large-size carbon fiber honeycomb components are typical difficult-to-machine materials, and are prone to various damages such as tearing, burrs, and edge collapse during machining, which seriously affect the surface forming quality and service performance of the workpiece. At the same time, the complex shape increases the machining difficulty and reduces the machining accuracy.
[0004] Traditional wire EDM primarily focuses on longitudinal cutting, which presents challenges for machining large workpieces, including excessive equipment height, large span, and low machining accuracy. Furthermore, during processing, the interaction between the cutting wire and the workpiece causes vibration and misalignment of the cutting wire. In transverse cutting, the machined portion forms a cantilever beam structure, which impacts the unmachined portion by compressing the cutting wire. Simultaneously, the reaction force of the cutting wire on the groove easily leads to groove wear, resulting in low machining accuracy and poor machining quality.
[0005] To address the shortcomings of existing large-size carbon fiber honeycomb component molding processes, such as low efficiency, low processing accuracy, and high processing costs, which hinder the development of large-size carbon fiber honeycomb components, a low-disturbance processing method and equipment for long-span carbon fiber honeycomb components is proposed. Summary of the Invention
[0006] To address the problems in existing technologies where cutting line vibration and cantilever beam compression interfere with the cutting line during the cutting of carbon fiber honeycomb components, leading to component tearing, edge collapse, and unstable processing quality, this invention provides a low-disturbance processing method and equipment for long-span carbon fiber honeycomb components.
[0007] Therefore, the present invention provides the following technical solution: A low-disturbance processing method for long-span carbon fiber honeycomb components, characterized by comprising the following steps: S1. Conduct a tensile test on the cutting line to obtain the relationship between the tensile force and strain on the cutting line; simultaneously measure the side length of the regular polygonal structure in the carbon fiber honeycomb component to be cut; S2. Install the same specification cutting line that has undergone tensile testing onto the processing device, and clamp the carbon fiber honeycomb component onto the base. When clamping, ensure that the diameter of one of the regular polygons in each regular polygon structure within the component is perpendicular to the cutting line in the horizontal direction. S3. Set the feed speed of the Y-axis servo transmission mechanism, and calculate the straight-line distance of each side of the regular polygon along the cutting path of the cutting line along the Y-axis based on the side length of the regular polygon structure. S4. Based on the straight-line distance of the cutting path corresponding to each side of the regular polygon, and combined with the set feed speed of the Y-axis servo transmission mechanism, calculate the time required for the cutting line to cut each side. S5. Combining the relationship between the cutting line tension and its strain obtained in S1, set the target elongation of the electric push rod when the cutting line cuts different sides of the regular polygon structure; S6. Start the motor to drive the guide wheel to rotate, which drives the cutting line to rotate synchronously; adjust the cutting line to the preset cutting height through the Z-axis servo transmission mechanism, and then drive the cutting line to feed along the Y-axis through the Y-axis servo transmission mechanism to carry out the cutting operation on the carbon fiber honeycomb component; during the cutting process, according to the cutting time of each side calculated in S4, and in conjunction with the corresponding target elongation set in S5, periodically adjust the elongation of the electric push rod to complete the mechanical limit defibrillation cutting of the carbon fiber honeycomb component.
[0008] Furthermore, the calculation of the target elongation corresponding to the electric actuator in step S5 includes the following steps: The formula for calculating the tension force after initial tensioning of the cutting wire after installation is as follows:
[0009] In the formula: The tension force after the cutting wire is initially tensioned, in N; The slope of the curve during the elastic change stage, with a value ranging from 120 to 150; This represents the strain after the cutting wire is initially tensioned. The intercept of the curve during the elastic change stage on the vertical axis, with a value ranging from 10 to 20; After installing and initially tensioning the cutting wire, the strain of the cutting wire is: The line length is , In the formula: The length of the cutting wire when it is initially tensioned, in mm; The initial length of the cutting wire before installation, in mm; When the edge of the cut regular polygon structure is perpendicular to the cutting line, the tension of the cutting line is: , should be The line length is , In the formula: The force exerted when a cutting line cuts a perpendicular edge, expressed in nanometers (N). The length of the cutting line when cutting a perpendicular edge, in mm; The angle between the inner side of the guide wheel and the cutting line, in degrees; The interaction force between the cutting line and the regular polygonal structure when cutting the vertical edge; the magnitude of which can be determined by a force sensor, in N. When the edges of the cut regular polygon structure are inclined to the cutting line, the tension of the cutting line is: , should be The line length is , The electric linear actuator corresponds to the target elongation when cutting the inclined edge. , , In the formula: The force exerted when the cutting line cuts the hypotenuse, expressed in N; The length of the cutting line when cutting the bevel, in mm; The angle between the small guide wheel and the outer side of the cutting line, in degrees; This is the interaction force between the cutting line and the regular polygon structure when cutting the hypotenuse. Its magnitude can be determined by a force sensor and is measured in N. This is the distance between the two small guide wheels; This is the distance between the two guide wheels located at both ends of the cutting segment of the cutting line.
[0010] A low-disturbance processing equipment for long-span carbon fiber honeycomb components for implementing the method includes a base, on which a Y-axis servo transmission mechanism is mounted in parallel, and a Z-axis servo transmission mechanism is vertically mounted at the output end of the Y-axis servo transmission mechanism. An upper frame is mounted at the output end of the Z-axis servo transmission mechanism, and a gantry plate is vertically mounted on the upper frame. The gantry plate is rotatably mounted with guide wheels and a motor that drives the guide wheels to rotate. The cutting line is wound around the guide wheels. The gantry plate is also fixed with a partition plate and a guide wheel adjustment mechanism. The lower end of the partition plate is aligned with the transverse cutting trajectory of the cutting line, and the thickness of the partition plate is less than the width of the processing gap formed by the cutting line. The guide wheel adjustment mechanism is used to adjust the tension and position of the cutting line to control its vibration.
[0011] Furthermore, the guide wheel adjustment mechanism includes a manual adjustment component, which includes a distance adjustment plate and a tensioning plate; the tensioning plate is slidably mounted on the distance adjustment plate, the distance adjustment plate is fixed on the gantry plate, a tensioning block is installed on the gantry plate, a screw is threaded through the tensioning block, and one end of the screw is rotatably connected to the tensioning plate; the number of guide wheels is four, one of which is rotatably mounted on the tensioning plate.
[0012] Furthermore, the guide wheel adjustment mechanism includes two electric adjustment components. Each electric adjustment component includes a connecting frame, a slide rail, an electric push rod, a force sensor, a load-bearing plate, and a small guide wheel. The connecting frame is fixed to the gantry plate, so that the two electric adjustment components are located on the same horizontal straight line and correspond to the cutting section height of the cutting line. The slide rail is installed on the connecting frame, and the load-bearing plate is slidably mounted on the slide table of the slide rail. The electric push rod is installed on the connecting frame, and the output end of the electric push rod is connected to the load-bearing plate. A small guide wheel seat is installed at the bottom of the load-bearing plate, and the small guide wheel is rotatably mounted on the small guide wheel seat and in contact with the cutting line. The force sensor is installed between the output end of the electric push rod and the small guide wheel seat.
[0013] Furthermore, an X-axis servo transmission mechanism is installed on the gantry plate, and the output end of the X-axis servo transmission mechanism is connected to an angle adjustment lower plate. An angle adjustment upper plate is rotatably mounted on the angle adjustment lower plate via a rotating shaft. The angle adjustment upper plate and the angle adjustment lower plate are positioned by a pin. A bearing seat is installed on the angle adjustment upper plate, and an electric spindle is installed on the bearing seat. The electric spindle is used to install cutting tools.
[0014] Furthermore, the lower angle adjustment plate has a square structure, and a slot is provided on the circumferential edge of the lower angle adjustment plate. The pin is engaged in the slot, and the pin limits and fixes the three sides of the upper angle adjustment plate.
[0015] Furthermore, the cutting wire is a metal wire with diamond abrasive grains electroplated on its surface, the wire diameter is 0.1~0.8mm, and the particle size of the diamond abrasive grains is 5~15μm; the separator plate is made of cemented carbide sheet, the thickness of the separator plate is 0.05~0.5mm, and the lower end of the separator plate is passivated.
[0016] Furthermore, it also includes a clamp mounted on the base and located below the cutting line for clamping and fixing large-sized carbon fiber honeycomb components to be processed.
[0017] Furthermore, both the base and the upper frame are welded from metal square tubing, and anchor bolts are installed at the bottom of the base.
[0018] Advantages and positive effects of the present invention: By pre-observing the tension and strain relationship of the cutting line and dynamically adjusting the extension of the electric push rod according to the cutting time of each side during the cutting process, the cutting line can always maintain stable tension, significantly reducing cutting line vibration and improving cutting accuracy.
[0019] The separator plate is precisely aligned with the cross-cutting trajectory of the cutting line, and its thickness matches the processing gap. It can enter the cutting seam synchronously with the cutting line, providing real-time support for the cantilever beam structure formed during cutting and preventing the cantilever beam from squeezing the cutting line due to its own weight or vibration.
[0020] This avoids processing defects such as tearing and edge collapse in large-size carbon fiber honeycomb components caused by the superposition of vibration and cantilever beam compression, and significantly improves the integrity of the component processing surface and the stability of processing quality. Attached Figure Description
[0021] 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.
[0022] Figure 1 This is a three-dimensional structural diagram of a low-disturbance processing equipment for long-span carbon fiber honeycomb components provided by the present invention.
[0023] Figure 2 The present invention provides a structural diagram of a manually adjustable component for a low-disturbance processing equipment for long-span carbon fiber honeycomb components.
[0024] Figure 3 This invention provides a structural diagram of a milling assembly for a low-disturbance machining equipment for long-span carbon fiber honeycomb components.
[0025] Figure 4 The present invention provides a structural diagram of an electrically adjustable component for a low-disturbance processing equipment for long-span carbon fiber honeycomb components.
[0026] Figure 5 This invention provides a state analysis diagram of the relationship between the small guide wheel and the cutting line during the cutting of a low-disturbance processing equipment for long-span carbon fiber honeycomb components.
[0027] Figure 6 This invention provides a force analysis diagram of a low-disturbance processing equipment for long-span carbon fiber honeycomb components when cutting vertical edges.
[0028] Figure 7 This invention provides a stress analysis diagram of a low-disturbance processing equipment for long-span carbon fiber honeycomb components when cutting inclined edges.
[0029] In the diagram: 1. Upper frame; 2. Guide wheel; 3. Divider plate; 4. Cutting line; 5. Gantry plate; 6. Material; 7. Z-axis servo transmission mechanism; 9. Y-axis servo transmission mechanism; 10. Base; 11. Anchor screw; 12. Distance adjustment plate; 13. Tensioning plate; 14. X-axis servo transmission mechanism; 15. Pin; 16. Lower angle adjustment plate; 17. Upper angle adjustment plate; 18. Shaft seat; 19. Electric spindle; 20. Connecting frame; 21. Slide rail; 22. Slide table; 23. Load-bearing plate; 24. Small guide wheel; 25. Force sensor; 26. Electric push rod; 27. Tensioning block; 28. Screw; 29. Small guide wheel seat. Detailed Implementation
[0030] To enable those skilled in the art to better understand the present invention, the technical solutions of the present invention will be clearly and completely described below with reference to the accompanying drawings of the embodiments of the present invention. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort should fall within the scope of protection of the present invention.
[0031] A low-disturbance processing method for long-span carbon fiber honeycomb components includes the following steps: S1. Conduct a tensile test on the cutting line 4 to obtain the relationship between the tensile force on the cutting line 4 and its elongation; simultaneously measure the side length of the regular polygonal structure in the carbon fiber honeycomb component to be cut.
[0032] S2. Install the same specification cutting line 4, which has undergone tensile testing, onto the processing device, and at the same time clamp the carbon fiber honeycomb component onto the base 10. When clamping, ensure that the diameter of one of the regular polygons in each regular polygon structure within the component is perpendicular to the cutting line 4 in the horizontal direction.
[0033] S3. Set the feed speed of the Y-axis servo transmission mechanism 9, and calculate the straight-line distance of each side of the regular polygon on the cutting path of the cutting line 4 along the Y-axis according to the side length of the regular polygon structure.
[0034] S4. Based on the straight-line distance of the cutting path corresponding to each side of the regular polygon, and combined with the set feed speed of the Y-axis servo transmission mechanism 9, calculate the time required for cutting line 4 to cut each side.
[0035] S5. Based on the relationship between the tension and elongation of the cutting line 4 obtained in S1, set the target elongation of the electric push rod 26 when the cutting line 4 cuts different sides of the regular polygon structure; for example... Figure 6As shown in the figure, the force analysis is performed when the cutting line cuts the vertical edge. Fa and Fb are the components of the cutting force acting on the vertical edge along the direction of the vertical edge and perpendicular to the vertical edge, respectively. Figure 7 As shown in the diagram, when cutting the hypotenuse, the force analysis reveals that when the force applied by the cutting line to the corresponding edge remains constant, the force components on the perpendicular edge and the hypotenuse are different. This difference in force components results in different deformations on the perpendicular edge and the hypotenuse. This change in force also causes strain changes in the cutting line when cutting the hypotenuse and the perpendicular edge, leading to vibration. Figure 5 As shown, the calculation of the target elongation corresponding to the electric push rod 26 in step S5 includes the following steps: The formula for calculating the tension force after initial tensioning of cutting wire 4 after installation is as follows:
[0036] In the formula: The tension force after the cutting wire is initially tensioned, in N; The slope of the curve during the elastic change stage, with a value ranging from 120 to 150; This represents the strain after the cutting wire is initially tensioned. The intercept of the curve during the elastic change stage on the vertical axis, with a value ranging from 10 to 20; After installing and initially tensioning the cutting wire 4, the strain of the cutting wire 4 is: The line length is , In the formula: The length of the cutting wire when it is initially tensioned, in mm; The initial length of cutting line 4 before installation, in mm; When the edge of the cut regular polygon structure is perpendicular to the cutting line 4, the tension of the cutting line is: , should be The line length is , In the formula: The force exerted when cutting the perpendicular edge by cutting line 4, in N; The length of the cutting line when cutting a perpendicular edge, in mm; The angle between the inner sides of the small guide wheel 24 and the cutting line 4 is expressed in degrees. The interaction force between the cutting line and the regular polygonal structure when cutting the vertical edge can be determined by the force sensor 25, in N; When the edge of the cut regular polygon structure is inclined to the cutting line 4, the tension of the cutting line is: , should be The line length is , Electric actuator 26 corresponds to the target elongation when cutting the inclined edge. , , In the formula: The force exerted when the cutting line cuts the hypotenuse, expressed in N; β is the length of the cutting line when cutting the bevel, in mm; β is the angle between the small guide wheel 24 and the outer side of the cutting line, in °. The interaction force between the cutting line and the regular polygonal structure when cutting the hypotenuse is known by the force sensor 25, in N; The distance between the two small guide wheels 24; The distance between the two guide wheels 2 located at both ends of the cutting segment of the cutting line 4.
[0037] S6. Start the motor to drive the guide wheel 2 to rotate, causing the cutting line 4 to rotate synchronously; adjust the cutting line 4 to the preset cutting height through the Z-axis servo transmission mechanism 7, and then drive the cutting line 4 to feed along the Y-axis through the Y-axis servo transmission mechanism 9 to perform cutting operations on the carbon fiber honeycomb component; during the cutting process, according to the cutting time of each side calculated in S4, and in conjunction with the corresponding target elongation set in S5, periodically adjust the elongation of the electric push rod 26 to complete the mechanical limit defibrillation cutting of the carbon fiber honeycomb component. When cutting the vertical edge, the elongation of the electric push rod 26 is the initial elongation; when cutting the inclined edge, the elongation of the electric push rod 26 is the target elongation. After the current bevel cutting is completed, the electric actuator 26 returns to its initial extension to cut the vertical edge, and this process is repeated. By adjusting the extension of the electric actuator 26, the tension of the cutting line remains constant when cutting the vertical and bevel edges, thereby achieving the defibrillation effect.
[0038] To achieve a low-disturbance processing method for long-span carbon fiber honeycomb components, this invention provides a low-disturbance processing equipment for long-span carbon fiber honeycomb components, such as... Figure 1 As shown, it includes a base 10, on which a Y-axis servo drive mechanism 9 is mounted in parallel. A Z-axis servo drive mechanism 7 is vertically mounted at the output end of the Y-axis servo drive mechanism 9. An upper frame 1 is mounted at the output end of the Z-axis servo drive mechanism 7. A gantry plate 5 is vertically mounted on the upper frame 1.
[0039] The base 10 is welded from a metal square tube, and the bottom of the base 10 is fitted with anchor screws 11. A guide wheel 2 and a motor that drives the guide wheel 2 to rotate are rotatably mounted on the gantry plate 5. The cutting line 4 is wound on the guide wheel 2. A partition plate 3 and a guide wheel adjustment mechanism are also fixed on the gantry plate 5. The lower end of the partition plate 3 is aligned with the transverse cutting trajectory of the cutting line 4, and the thickness of the partition plate 3 is less than the width of the processing gap formed by the cutting line 4. The guide wheel adjustment mechanism is used to adjust the tension and position of the cutting line 4 to control its vibration. The guide wheel adjustment mechanism includes a manual adjustment component, such as... Figure 2 As shown, the manual adjustment assembly includes a distance adjustment plate 12 and a tensioning plate 13; the tensioning plate 13 is slidably mounted on the distance adjustment plate 12, the distance adjustment plate 12 is fixed on the gantry plate 5, a tensioning block 27 is installed on the gantry plate 5, a screw 28 is threaded through the tensioning block 27, and one end of the screw 28 is rotatably connected to the tensioning plate 13; there are four guide wheels 2, one of which is rotatably mounted on the tensioning plate 13.
[0040] The guide wheel adjustment mechanism includes an electric adjustment component, such as... Figure 4 As shown, there are two electric adjustment components. Each electric adjustment component includes a connecting frame 20, a slide rail 21, an electric push rod 26, a force sensor 25, a load-bearing plate 23, and a small guide wheel 24. The connecting frame 20 is fixed on the gantry plate 5, so that the two electric adjustment components are located on the same horizontal straight line and correspond to the cutting section height of the cutting line 4. The slide rail 21 is installed on the connecting frame 20. The load-bearing plate 23 is slidably mounted on the slide table 22 of the slide rail 21. The electric push rod 26 is installed on the connecting frame 20. The output end of the electric push rod 26 is connected to the load-bearing plate 23. A small guide wheel seat 29 is installed at the bottom of the load-bearing plate 23. The small guide wheel 24 is rotatably installed on the small guide wheel seat 29 and is in contact with the cutting line 4. The force sensor 25 is installed between the output end of the electric push rod 26 and the small guide wheel seat 29.
[0041] The cutting line 4 is a metal wire with diamond abrasive grains electroplated on its surface. The diameter of the cutting line 4 is 0.1~0.8mm and the particle size of the diamond abrasive grains is 5~15μm. The separator plate 3 is made of cemented carbide plate. The thickness of the separator plate 3 is 0.05~0.5mm and the lower end of the cutting edge of the separator plate 3 is passivated.
[0042] An X-axis servo drive mechanism 14 is installed on the gantry plate 5. The output end of the X-axis servo drive mechanism 14 is connected to an angle adjustment lower plate 16, such as... Figure 3 As shown, the lower angle adjustment plate 16 is rotatably mounted with the upper angle adjustment plate 17 via a rotating shaft. The upper angle adjustment plate 17 and the lower angle adjustment plate 16 are positioned by a pin 15. A bearing seat 18 is mounted on the upper angle adjustment plate 17, and an electric spindle 19 is mounted on the bearing seat 18. The electric spindle 19 is used to mount cutting tools.
[0043] like Figure 3 As shown, the lower angle adjustment plate 16 has a square structure. The circumferential edge of the lower angle adjustment plate 16 has a slot, and the pin 15 is engaged in the slot. The pin 15 also limits and fixes the three sides of the upper angle adjustment plate 17.
[0044] It also includes a clamp, which is mounted on the base 10 and located below the cutting line 4, for clamping and fixing the large-sized carbon fiber honeycomb components to be processed.
[0045] Working principle This device forms an overall support frame through a base 10 and an upper frame 1. The base 10 is welded from metal square tubing, combining lightweight and high rigidity, effectively bearing the load during processing and suppressing overall deformation. Anchor screws 11 installed at the bottom can precisely level the device and secure it to the ground, avoiding processing deviations caused by device shaking during processing. Before processing, the material 6 of the large-sized carbon fiber honeycomb component to be processed is clamped on the fixture of the base 10 for positioning and fixation, ensuring no displacement of the component during processing.
[0046] The screw 28 drives the tension plate 13 to slide along the distance adjustment plate 12, which can finely adjust the spacing of the guide wheel 2 to achieve precise pre-tensioning of the cutting line 4, avoiding cutting deviation caused by the slack of the cutting line. At the same time, the arrangement of the four guide wheels forms a low span cutting circuit, which solves the problem of excessive equipment height and large span in the traditional processing of large-size components, and significantly improves the cutting accuracy.
[0047] The electric push rod 26 is activated to push the load-bearing plate 23 to slide along the slide rail 21, so that the small guide wheel 24 is in close contact with the cutting line 4. During the cutting process, the vibration force generated by the contact between the cutting line 4 and the component is transmitted to the force sensor 25 through the small guide wheel 24. The force sensor 25 feeds back the force signal to the external control system in real time, driving the electric push rod 26 to dynamically adjust the pressure of the small guide wheel 24, so as to realize the active and precise control of the vibration of the cutting line, and effectively avoid problems such as wear of the groove of the small guide wheel 24 and rough cutting surface caused by vibration.
[0048] The Y-axis and Z-axis servo transmission mechanisms work together to drive the gantry plate 5, causing the cutting line 4 and the partition plate 3 to feed synchronously. During the cutting process, the linear speed of the cutting line 4 is 5~10m / s; the partition plate 3 extends precisely into the cutting kerf along with the cutting line 4. Because the thickness of the partition plate is adapted to the processing gap and it is made of hard alloy material, it can stably support and lift the cantilever beam structure that has been processed, completely eliminating the impact of its compression of the cutting line 4 on the unprocessed part, avoiding damage such as tearing and edge collapse of the components, and ensuring processing quality.
[0049] Pulling out the pin 15 and rotating the angle adjustment upper plate 17 allows the electric spindle 19 to quickly switch between horizontal (avoiding wire cutting) and vertical (milling) positions. Then, inserting the pin 15 into the slot of the angle adjustment lower plate 16 creates a three-sided limit on the angle adjustment upper plate 17, ensuring precise and stable positioning and preventing spindle angle deviation during milling. This structure eliminates the need for additional drive components, achieving a compact design that integrates milling and cutting, and solving the problem of low efficiency caused by separate wire cutting and milling operations in traditional machining processes.
[0050] After installing a cutting tool (such as a milling cutter, disc cutter, drill bit, etc.) at the output end of the electric spindle 19, the X-axis servo drive mechanism is activated to drive the electric spindle 19 to feed. In conjunction with the Y-axis and Z-axis servo drive mechanisms, milling, drilling, or grooving is performed on the top surface of the component that has undergone wire cutting. Both machining processes can be completed without transferring the component, significantly shortening the machining cycle, reducing secondary positioning errors during transport, and further improving overall machining accuracy.
[0051] 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-disturbance processing method for long-span carbon fiber honeycomb components, characterized in that, Includes the following steps: S1. Conduct a tensile test on the cutting line (4) to obtain the relationship between the tensile force on the cutting line (4) and its elongation; Simultaneously measure the side length of the regular polygonal structure in the carbon fiber honeycomb component to be cut; S2. Install the same specification cutting line (4) that has been tested for tensile strength onto the processing device, and at the same time clamp the carbon fiber honeycomb component onto the base (10). When clamping, ensure that the diameter of one of the regular polygons in each regular polygon structure in the component is perpendicular to the cutting line (4) in the horizontal direction. S3. Set the feed speed of the Y-axis servo transmission mechanism (9), and calculate the straight-line distance of each side of the regular polygon on the cutting path of the cutting line (4) along the Y-axis according to the side length of the regular polygon structure. S4. Based on the straight-line distance of the cutting path corresponding to each side of the regular polygon, and combined with the set feed speed of the Y-axis servo transmission mechanism (9), calculate the time required for the cutting line (4) to cut each side; S5. Based on the relationship between the tension and elongation of the cutting line (4) obtained in S1, set the target elongation of the electric push rod (26) when the cutting line (4) cuts different sides of the regular polygon structure. S6. Start the motor to drive the guide wheel (2) to rotate, and drive the cutting line (4) to rotate synchronously; adjust the cutting line (4) to the preset cutting height through the Z-axis servo transmission mechanism (7), and then drive the cutting line (4) to feed along the Y-axis through the Y-axis servo transmission mechanism (9) to carry out cutting operations on the carbon fiber honeycomb components; During the cutting process, the cutting time of each side is calculated according to S4, and the corresponding target elongation is set in S5. The elongation of the electric push rod (26) is periodically adjusted to complete the mechanical limiting and defibrillation cutting of the carbon fiber honeycomb component.
2. The low-disturbance processing method for long-span carbon fiber honeycomb components according to claim 1, characterized in that, The calculation of the target elongation of the electric push rod (26) in step S5 includes the following steps: The formula for calculating the tension force after initial tensioning of the cutting wire (4) after installation is as follows: In the formula: The tension force after the cutting wire is initially tensioned, in N; The slope of the curve during the elastic change stage, with a value ranging from 120 to 150; This represents the strain after the cutting wire is initially tensioned. The intercept of the curve during the elastic change stage on the vertical axis, with a value ranging from 10 to 20; After installing the cutting wire (4) and initially tensioning it, the strain of the cutting wire (4) is: The line length is , In the formula: The length of the cutting wire when it is initially tensioned, in mm; The initial length of the cutting line (4) before installation, in mm; When the edge of the cut regular polygon structure is perpendicular to the cutting line (4), the tension of the cutting line is , should be The line length is , In the formula: The force (in N) when the cutting line (4) cuts the vertical edge; The length of the cutting line when cutting a perpendicular edge, in mm; The angle between the inner sides of the small guide wheel (24) and the cutting line (4) is expressed in degrees. The interaction force between the cutting line and the regular polygon structure when cutting the vertical edge can be determined by the force sensor (25), in N; When the edges of the cut regular polygon structure are inclined to the cutting line (4), the tension of the cutting line is... , should be The line length is , The electric actuator (26) corresponds to the target elongation when cutting the inclined edge. , ， In the formula: The force exerted when the cutting line cuts the hypotenuse, expressed in N; β is the length of the cutting line when cutting the bevel, in mm; β is the angle between the small guide wheel (24) and the outer side of the cutting line, in °. The interaction force between the cutting line and the regular polygon structure when cutting the hypotenuse can be determined by the force sensor (25), in N; The distance between the two small guide wheels (24); The distance between the two guide wheels (2) located at both ends of the cutting segment of the cutting line (4) is denoted as .
3. A low-disturbance processing equipment for long-span carbon fiber honeycomb components to implement the method of any one of claims 1-2, characterized in that, Includes a base (10), on which a Y-axis servo transmission mechanism (9) is mounted in parallel, and a Z-axis servo transmission mechanism (7) is mounted vertically at the output end of the Y-axis servo transmission mechanism (9), and an upper frame (1) is mounted at the output end of the Z-axis servo transmission mechanism (7), and a gantry plate (5) is mounted vertically on the upper frame (1). The gantry plate (5) is rotatably mounted with a guide wheel (2) and a motor that drives the guide wheel (2) to rotate. The cutting line (4) is wound around the guide wheel (2). The gantry plate (5) is also fixed with a partition plate (3) and a guide wheel adjustment mechanism. The lower end of the partition plate (3) is directly opposite to the transverse cutting trajectory of the cutting line (4), and the thickness of the partition plate (3) is less than the width of the processing gap formed by the cutting line (4). The guide wheel adjustment mechanism is used to adjust the tension and position of the cutting line (4) to control its vibration.
4. The low-disturbance processing equipment for long-span carbon fiber honeycomb components according to claim 3, characterized in that, The guide wheel adjustment mechanism includes a manual adjustment component, which includes a distance adjustment plate (12) and a tension plate (13). The tension plate (13) is slidably mounted on the distance adjustment plate (12), and the distance adjustment plate (12) is fixed on the gantry plate (5). A tension block (27) is installed on the gantry plate (5). A screw (28) is threaded through the tension block (27), and one end of the screw (28) is rotatably connected to the tension plate (13). There are four guide wheels (2), one of which is rotatably mounted on the tension plate (13).
5. The low-disturbance processing equipment for long-span carbon fiber honeycomb components according to claim 3, characterized in that, The guide wheel adjustment mechanism includes two electric adjustment components. Each electric adjustment component includes a connecting frame (20), a slide rail (21), an electric push rod (26), a force sensor (25), a load-bearing plate (23), and a small guide wheel (24). The connecting frame (20) is fixed on the gantry plate (5) so that the two electric adjustment components are located on the same horizontal straight line and correspond to the height of the cutting section of the cutting line (4). The slide rail (21) is mounted on the connecting frame (20). The load-bearing plate (23) is slidably mounted on the slide table (22) of the slide rail (21). The electric push rod (26) is mounted on the connecting frame (20). The output end of the electric push rod (26) is connected to the load-bearing plate (23). A small guide wheel seat (29) is installed at the bottom of the load-bearing plate (23). The small guide wheel (24) is rotatably mounted on the small guide wheel seat (29) and is in contact with the cutting line (4). The force sensor (25) is installed between the output end of the electric push rod (26) and the small guide wheel seat (29).
6. The low-disturbance processing equipment for long-span carbon fiber honeycomb components according to claim 3, characterized in that, An X-axis servo transmission mechanism (14) is installed on the gantry plate (5). The output end of the X-axis servo transmission mechanism (14) is connected to an angle adjustment lower plate (16). An angle adjustment upper plate (17) is mounted on the angle adjustment lower plate (16) via a rotating shaft. The angle adjustment upper plate (17) and the angle adjustment lower plate (16) are positioned by a pin (15). A bearing seat (18) is installed on the angle adjustment upper plate (17). An electric spindle (19) is installed on the bearing seat (18). The electric spindle (19) is used to install cutting tools.
7. The low-disturbance processing equipment for long-span carbon fiber honeycomb components according to claim 6, characterized in that, The lower angle adjustment plate (16) has a square structure. A slot is provided on the circumferential edge of the lower angle adjustment plate (16). The pin (15) is engaged in the slot, and the pin (15) limits and fixes the three sides of the upper angle adjustment plate (17).
8. The low-disturbance processing equipment for long-span carbon fiber honeycomb components according to claim 3, characterized in that, The cutting line (4) is a metal wire with diamond abrasive grains electroplated on its surface. The diameter of the cutting line (4) is 0.1~0.8mm and the particle size of the diamond abrasive grains is 5~15μm. The separator plate (3) is made of hard alloy plate. The thickness of the separator plate (3) is 0.05~0.5mm and the lower edge of the separator plate (3) is passivated.
9. The low-disturbance processing equipment for long-span carbon fiber honeycomb components according to claim 3, characterized in that, It also includes a clamp mounted on the base (10) and located below the cutting line (4) for clamping and fixing the large carbon fiber honeycomb component to be processed.
10. The low-disturbance processing equipment for long-span carbon fiber honeycomb components according to claim 3, characterized in that, The base (10) and the upper frame (1) are both welded from metal square tubes, and the bottom of the base (10) is fitted with anchor screws (11).