高性能复杂薄壁曲面覆层天线精密高效加工基础理论与技术

As the key parts of the high-speed vehicle in aerospace engineering field, the complex thin-walled curved surface cladding antenna with high-performance has some features such as complex structure, low stiffness, etc. Meanwhile, the requirements are high for the edge quality of the antenna line and the geometric accuracy of the antenna. The complex thin-walled curved surface cladding antenna with high-performance can be regarded as a kind of complex thin-walled curved surface parts with surface function structure and the existing processing method restricted by machining precision is difficult to ensure the performance requirement for such parts, which also results in restricting the development of high-speed vehicle. By analyzing the structure characteristics and the machining process for this kind of parts, the reliable clamping method with homogeneous deformation for the complex thin-walled curved surface will be studied. On this basis, the tool path re-planning method will be researched for the surface function structure on complex thin-walled curved surface in the clamping state by using the original design, a time-variable feed-speed planning strategy on account of the dynamic contour error will also be established, and then the processing technology optimization method on the condition of time-variable feed-speed can be proposed for the surface function structure on complex thin-walled curved surface, which will provide theoretical and technical supports for high precision and efficient processing of the complex thin-walled curved surface cladding antenna with high-performance. After comprehensive processing experiment, high precision and efficient processing for the complex thin-walled curved surface cladding antenna with high-performance can be achieved. The research results have important theoretic significance to guarantee the machining precision, improve the machining efficiency for the complex thin-walled curved surface cladding antenna with high-performance, which can meet the demand of high-speed vehicle, and then can be as a result to provide technical supports for the high precision and efficient processing of other thin-walled curved surface parts with complex geometrical feature in the high-end equipments.

高性能复杂薄壁曲面覆层天线作为航空航天领域高速飞行器中的关重件，具有结构复杂、刚度低、带线边缘质量、几何精度要求高等特点，是一种典型的具有表层功能结构的复杂薄壁曲面零件，现有加工方法受加工精度限制难以保证此类零件性能要求，制约高速飞行器发展。在分析该类零件结构特征及加工工艺的基础上，研究变形顺应均匀的复杂薄壁曲面可靠装夹方法，突破基于原始设计的夹紧态薄壁曲面表层功能结构加工轨迹再规划技术，建立基于动态轮廓误差的加工时变进给速度规划策略，提出时变进给速度下复杂薄壁曲面表层功能结构加工工艺优化方法，为高性能复杂薄壁曲面覆层天线的精密高效加工提供理论与技术支撑。通过加工综合试验，实现高性能复杂薄壁曲面覆层天线精密高效加工。研究成果对保证高性能复杂薄壁曲面覆层天线加工精度、提高加工效率、满足高速飞行器发展需求具有重要意义，亦为我国高端装备中具有复杂几何特征的薄壁结构件精密高效加工提供技术支撑。

高性能复杂薄壁曲面覆层天线是航空航天领域典型关重件，兼具结构复杂、刚度柔弱、图案高边缘质量与几何精度等加工难点，而先进激光加工技术为其表层图案制造提供了有效手段。面向复杂薄壁曲面件表层功能结构精密高效加工急需，开展了相关基础理论与技术研究。针对装夹变形问题，设计了薄壁回转件专用夹具，通过优化定位及夹紧元件布置，形成变形顺应均匀的复杂薄壁曲面可靠装夹方法。针对加工面夹紧态偏差问题，提出了基于原始设计的表层功能结构加工轨迹优化方法，建立自由态与夹紧态的刀位点映射模型，进而以图案尺寸与轮廓偏差阈值为约束，虑及曲面曲率导致瞬时加工参数变化，进行了局部轨迹点调整，经轨迹再规划烧蚀深度和烧蚀宽度精度分别提高14.36%和13.02%。针对激光刻蚀斜坡状边缘问题，建立了移动脉冲激光烧蚀形貌解析计算模型，基于加工参数影响特点提出刻蚀+侧壁修整的激光铣削侧壁锥角抑制工艺，相同烧蚀宽度和深度下边缘侧壁锥角抑制度超过90%。立足单一扫描策略在图案轮廓精度与进给速度可达性间的矛盾，发展了激光双扫描策略轨迹配置方法，图案外区环扫加工保证轮廓精度，图案内区行扫加工保证扫描速度，以机床进给速度可达性建立分区准则，实验表明图案轮廓平滑且中心区过烧水平由23μm降至1μm。最后集成研究内容开发了复杂薄壁曲面零件表层图案激光精密加工专用CAM软件，实现激光刻蚀仿真、参数计算、轨迹规划的一体化。通过加工综合试验，实现了多种复杂薄壁曲面覆层图案典型试件精密高效加工。研究成果对保证高性能复杂薄壁曲面覆层天线加工精度、提高加工效率、满足高速飞行器发展需求具有重要意义，亦为我国高端装备中具有复杂几何特征的薄壁结构件精密高效加工提供技术支撑。