适用于航天控制系统零件精密内孔加工的高效电火花铣削技术  

Efficient EDM Milling Technology for Precise Internal Hole Machining of Aerospace Control System Components

作　　者：褚皓宇 王健 朱力敏 罗春 申振丰 奚学程[2] 赵万生[2] Chu Haoyu;Wang Jian;Zhu Limin;Luo Chun;Shen Zhenfeng;Xi Xuecheng;Zhao Wansheng(Shanghai Aerospace Control Technology Institute,Shanghai 201108;School of Mechanical Engineering,Shanghai Jiao Tong University,Shanghai 200240)

机构地区：[1]上海航天控制技术研究所,上海201108 [2]上海交通大学机械与动力工程学院,上海200240

出　　处：《航天制造技术》2024年第2期33-36,共4页Aerospace Manufacturing Technology

基　　金：国家自然科学基金项目(52****33)。

摘　　要：高效电火花铣削技术着眼于提升航天控制系统精密零件内孔加工的效率与精度,通过将高速电火花加工方法与传统铣削工艺相融合,突破传统电火花加工内孔需制备对应形状电极、加工效率低、几何精度差、再铸层厚度难以控制的限制,从电极损耗补偿和自适应过程控制、实时速度控制及轨迹规划、再铸层与表面质量控制方法等三方面出发,探索高效电火花铣削加工在复杂孔系壳体类、精密轴套类以及功能微孔类零件加工中的应用。该方法与传统电火花成形加工精密内孔相比,可将加工效率提升65%,同时最高可降低87.17%的再铸层厚度值,实现了精密内孔加工效率、质量与成本的多重提升。随着高效电火花铣削技术在精密加工中的广泛应用,将大幅提高航天控制系统关键零部件的制造能力,同时能够为日益增多的零件种类以及日益复杂的零件结构,提供更加全面的工艺解决方案。Efficient EDM(electrical discharge machining)milling technology focuses on improving the efficiency and accuracy of precise internal holes machining in aerospace control system components.By integrating fast EDM drilling with traditional milling method,this novel method breaks through the limitations of traditional EDM,such as the need to prepare corresponding shaped electrodes,low machining efficiency,poor geometric accuracy and thick recast layer.This method includes electrode loss compensation and adaptive process control,real-time speed control and trajectory planning,recast layer and surface quality control,which explores the application of EDM milling in the machining of complex holes shells,precision shaft sleeves and functional micro-porous components.According to the experimental results,it is found that the efficient EDM milling can increase the machining rate by 65%compared to traditional EDM machining of precise internal holes.Meanwhile,this method can reduce 87.17%thickness of recast layer,achieving multiple improvements in precise internal holes machining efficiency,quality and cost.With the widespread application of efficient EDM milling in precision machining,the manufacture capacity of aerospace control system components will be greatly improved.This method also can provide more comprehensive process solutions for an increasing number of component types and increasingly complex component structures.

关 键 词：航天控制系统 精密内孔 高速电火花小孔加工 铣削加工 再铸层 

分 类 号：TG661[金属学及工艺—金属切削加工及机床] V461[航空宇航科学与技术—航空宇航制造工程]