面向快速制造的特种加工理论与技术基础

The project is undertaken by Dalian University of Technology, Harbin Institute of Technology, and Nanjing University of Aeronautics and Astronautics together. To meet the need of rapid manufacturing and its application, new and far-reaching non-conventional machining technologies were developed on the basis of summarizing the mature non-conventional machining technologies. The non-conventional machining technologic system oriented rapid manufacturing was established through the research of technologic laws, modeling theories and methods, intelligent control techniques, and the emphasized combined technologies with high efficiency and precision.Several partial contents were included in the project: 1. Theoretic and technical basis of EDM and Ultrasonic Machining based on laminated manufacturing and simple tool. 2. Machining technique through the combination of erosion with cutting based on electric field control. 3. Machining technique for three-dimension cavity through the combination of precise machining with mirror-like surface EDM. 4. Non-conventional machining theories and technologies based on rapid prototyping and manufacturing, and combined non-conventional machining technologies oriented rapid prototyping and manufacturing. 5.Modeling and intelligent control technique for non-conventional machining process. 6.Non-conventional machining technical system oriented rapid manufacturing, and selective and estimate system for non-conventional machining technologies.Achievements were made in the research of the project: 1. Slicing method based on STL file and IGES file was researched, and the method suit for creating NC locus of laminated EDM machining and Ultrasonic Machining is advanced. The wearing law of tool and electrode was found out through theoretical and experimental analysis, and the mathematical compensating model was thus established. The CAD/CAM software based on Windows operation system was also developed. Through the method, 40-pin IC chip mold and submillimetre complicated three-dimension metal and ceramic cavities were successfully manufactured. 2.An electrochemistry machining method through time-variable field and auxiliary magnetic field control was developed, and a time-variable field controlled ELID grinding method was established. Complicated revolution surface with high machining precision(micron level) and high surface finish quality(Ra≤0.02mm) was achieved. 3.The mechanism model of powder-mixed EDM was established through deep research, and the optimized technologic parameter was summarized through experiments. Large acreage mirror-like surface (minimum Ra0.107mm and average Ra0.15mm) was achieved, and a new powder-mixed EDM device for mirror finishing with independent intellectual patent was developed. 4. Based on rapid prototyping, a rapid and economical technique for rapid manufacturing metal parts, molds and tools was investigated through the combination of investment casting, wire-arc spraying, electroforming and EDM. To fabricate large bulk nanometer metal materials, an original method of producing free form nanometer crystal copper through electroforming was advanced. High hardness and fracture strength nanometer copper can be fabricated through the method. 5. The decision-making capability of EDM technologic design was improved by artificial intelligent methods such as expert system, manual NN, genetic algorithm and fuzzy control. The frame of EDM intelligent decision-making system based on integrated intelligence and self-learning was successfully constructed, and the computer simulation of EDM process was realized. 6.The structure of technological decision-making system by network was advanced, and an EDM decision-making system based on WWW was established on Internet. In the system, web server was established through IIS3.0 of Windows NT; EDM technological database was constructed through SQL Server; dynamic interactive processing was achieved through ASP. The network of technological design was thus realized by the means. All the achievements above are significant for further de

研究基于分层制造思想，利用简单工具的电加工工艺新方法与理论，时变场控制电化学，机械，磁粒及磁场等相结合的复合加工方法与理论，三维型面的精密成型及镜面加工一体化技术基础，基于RP技术的特种加工方法及面向RP技术的特种加工工艺组合技术，形成面向快速制造的特种加工理论与技术体系，为并行工程、敏捷制造及虚拟制造提供理论及技术支撑。