Abstract: At this stage,titanium alloy materials have gradually become the main raw materials of large-scale precision castings.In order to effectively solve the practical production problems existing in the NC machining process,such as complicated process flow,difficult to control machining deformation,poor local rigidity of castings and difficult machining of local characteristics,it is necessary to start from residual detection The positioning mode and process equipment are studied,and the targeted optimization strategy is designed to improve the CNC machining mechanism of titanium alloy castings.
Key words:application analysis；technical research；CNC machining；titanium alloy
1 Introduction
In the field of industry, numerical control technology gradually applied in the process of mechanical mold manufacturing, not only makes the actual production efficiency greatly improved, and,reduce the industrial production cost, but also ensure the overall quality of mechanical products numerical control machining technology is widely used in the process of industrial production, make the development of industrial enterprises got significantly accelerated, the economic benefit is straight line. In this context, the titanium alloy material itself has the characteristics of good mechanical properties, high basic strength and strong corrosion resistance, so it is widely used in the production process of modern industry. Titanium alloy casting can not only inherit many advantages of titanium alloy materials, but also can easily and effectively make large, thin-wall complex structure molding, so as to improve the utilization rate of raw materials, effectively, reduce the workload of mechanical processing, optimize the production cycle to a certain extent, reduce the cost of CNC processing.
1 Application analysis of titanium alloy cast-casting
1.1Analysis of processing characteristics of titanium alloy precision castings
Against the backdrop of a growing economic strength, China's comprehensive development capacity is constantly improving, Among them, the degree of industrialization deepens in the process of industrial modernization, Modern industry dominated by mechanical mold industry is in full swing, The continuous optimization of industrial technologies such as CNC machining technology, The social market straightforwardness requirements for the work efficiency and work quality of CNC machining. Because the overall structure of titanium alloy precision casting is more complex,Coupled with problems such as weak local rigidity,The production and processing process of large titanium alloy precision castings is more coordinated and more complex, It is quite difficult to control the deformation of the casting, Therefore, in the CNC machining for the processing process control requirements and the degree of perfection of the process chem are very high requirements, Specifically reflected in the following three points: first of all,in the CNC machining process needs to locate the processes more, Thus, repeated positioning issue scan arise, And CNC processing when the clamping work is more difficult; Secondly, the amount of material removal and the partial allowance of the casting are not uniform enough, For example, in the process of CNC processing is prone to processing.
1.2 Characteristics of large titanium alloy precision castings
The first aspect is the characteristics of large titanium alloy precision castings in terms of part structure. Large titanium alloy precision castings are generally parts of the overall frame type. As shown in Figure 1, the net height in the Z direction is usually above 650 mm, and the effective support area inside the component is small, and the local rigidity of the component is relatively poor. There are relatively many thin-walled structures on the surface of the casting, and most of the thickness of the ribs is 2-3mm, and the mach inability is relatively poor ; titanium alloy precision castings generally also have four diameter steps of the focus hole and deep groove cavity lugs and so on numerical control processing is very difficult structure, at the same time, the groove width, coaxial and aperture construction accuracy requirements are also very high.
The second aspect is the blank characteristics of the casting. Although the blank size of titanium alloy refined casting has been basically fixed at present, it is difficult to control the accuracy error in the process of forging of titanium alloy casting, so the following two problems are easy: on the one hand, the surface is difficult to appear in the machining process, which greatly increases the actual workload of fitter grinding work; on the other side, the surface will increase the problem of uneven machining allowance of the casting, leading to the serious deformation of the casting during the CNC machining operation.
The third aspect is the analysis of the deformation characteristics of the parts. If the stress distribution of the titanium alloy large precision castings is not uniform, it is easy to cause serious deformation problems of the titanium alloy castings. Because most of the large titanium alloy precision castings are semi-closed frame structure, and the internal strong support is less, the rear end face of the precision casting will also show an open structure, the rigidity of the part structure is poor, and the process rib structure is not strengthened, so it is easy to appear in the process. Deformation problems such as opening end tension, height direction dislocation and surface bending, the main deformation factors include excessive removal of local materials and uneven release of internal stress. After the blank casting, the micro-structure distribution of the precision casting is not uniform enough, which leads to the problem that the thermal stress release is not balanced enough.
1.3The development process of titanium alloy precision casting technology
In different periods, the forging technology and quality control process of titanium alloy precision castings have different characteristics, and are constantly improving and optimizing. Different process periods correspond to the following technologies :
First, ordinary casting technology. In the early stage of the application of titanium alloy precision casting technology, the process was mainly used to produce medium-sized ordinary precision castings with medium size and simple shape. Most of the sizes of this type of precision castings are within 500 mm, and the shapes are mostly rod-shaped, disc-shaped, flat-shaped or ring-shaped, etc., and most of the wall thickness is within the range of 6-10 mm, such as prostheses implanted into the human body, engine blades and struts. Because there are no more complex process structures such as deep grooves, grooves and ribs, the structural stress during pouring is relatively small and the feeding is sufficient, and the forming process of this type of casting is relatively simple, so the forming quality can always be maintained in a relatively high quality state.
The second is a relatively large thin-walled complex casting, which is a type of casting that has been continuously developed to meet the practical application needs of the aerospace industry. With the gradual popularity of the aerospace field, the application of this type of casting forming technology has become the key research object of various large research institutions. The size of large thin-walled complex castings is mostly strictly controlled at 500-1000 mm, the wall thickness is 1-3 mm, and the structure is more complex, and the forming is very difficult.
Finally, it is a super-large integrally formed casting. At present, in the more developed countries abroad, the forging technology of super-large titanium alloy integral forming precision castings has been fully mature. However, it is still in its infancy in China.Such castings cannot be compared with other castings in terms of quality and performance. The size of this type of castings is mostly above 1500mm, the minimum wall thickness is about 1mm, and the mass is mostly about 50-1000kg. This type of casting is often used to replace the structure formed by the assembly of a large number of fasteners and parts, thereby comprehensively improving the stability and accuracy of the casting structure, and significantly reducing costs and accelerating production speed. The research and technical application of super large integral forming castings is the research difficulty of forging technology of titanium alloy precision castings in China at present, and it is also the focus of future research.
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2 Analysis of CNC machining technology scheme for large titanium alloy precision castings
On the basis of the systematic analysis of the structural characteristics of large titanium alloy precision castings and the actual processing difficulties, the numerical control machining technology scheme is formulated, including several main links of clamping, rapid positioning, deformation control and dimensional precision control: The first is the application scheme of the clamping technology, Since the upper half of the large titanium alloy precision casting structure is mostly in a free state, As shown in Figure Figure 22, Therefore, the openings at both ends of the casting and the large holes in the middle, Its rigidity is relatively weak, usually, Are prone to vibration problems during processing, Have a negative impact on the quality of the CNC machining Facing this problem, You can choose to add three additional sets of adjustable support tooling on the CNC machining platform, Effective enhancement of titanium alloy cast-casting requires the actual stiffness of the CNC machining part, So as to ensure the quality and performance of the surface.
The second is the rapid positioning method. Rapid positioning work is set in the processing platform of the tooling part of the fixed positioning pin device,
and in the casting processing technology convex, the corresponding position set hole structure, ensure the hole shaft clearance can echo, thus, in the process of numerical control processing to realize fast and accurate positioning: at the same time, in the tooling origin positioning pin need to be cylindrical, distal positioning pin, need to be designed as hexagon, thus on the basis of better fixed casting processing deformation for the casting, to lay the foundation for the subsequent clamping operation.
The third is the deformation control treatment. First is the cutting tool and related parameter optimization, in the cutting casting, cutting force is one of the biggest factors affecting casting quality largely determines the titanium alloy casting cutting heat and processing deformation problem, and even affect the actual efficiency of cutting, so in the process of cutting work, usually, will choose the blade sharp or front Angle is large sharp tool, and will adopt, small cutting deep layered processing method, so as to reduce the probability of titanium alloy casting deformation in numerical control machining process., The second is the realization of no stress repair, under the influence of all kinds of processing stress, titanium alloy refined casting will appear a, fixed deformation problem, in this case, it is necessary to
use no stress clamp and no stress repair method, weaken the deformation of the casting in large titanium alloy refined casting in the free state, using copper gasket pad, the bottom of the platform, ensure that the parts, and positioning platform, no deformation problem, so as to eliminate the process of loading stress and deformation of casting The fourth is the size accuracy control scheme, before the start of the CNC machining work, need to fully measure the processing surface and the machining surface, to facilitate subsequent deformation, quantity and machining allowance inspection work, and through the inspection results determine the CNC machining allowance in the actual CNC machining process, due to the large titanium alloy casting thin wall structure of obvious knife problem, so the number of precision casting, control machining accuracy is vulnerable to adverse influence, eventually lead to uneven local allowance and size difference. Finally from the perspective of the overall process analysis, the traditional NC technology process generally includes 25 technical process, there are more benchmark proofreading, spare check, clamping operation and fitter grinding complex process, parts, the turnover of too much, but the processing efficiency is relatively low, under the background of the development of electronic information technology, CNC machining technology in the process of optimization innovation gradually combined with advanced technology, process equipment and CNC equipment, and optimize on the original technical process, optimization of nc processing only 12 process. Therefore, from the perspective of size precision control, deformation control processing, rapid positioning and clamping operation, a complete and high-quality CNC machining scheme can be established, so as to ensure the CNC machining effect of large titanium alloy precision casting.
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3 Strategies to optimize the application effect of CNC machining technology for large titanium alloy precision castings
3.1 Comprehensive improvement of CNC machining technology to improve its applicability
With the overall improvement of China 's industrial level, the market competition in the industrial market has become increasingly fierce. If industrial enterprises want to be in a favorable position in the fierce market competition, maintain their market position, and obtain higher social and economic benefits, they need to carry out comprehensive and in-depth research on the overall development trend of the industrial market while carrying out production optimization reform. The corresponding improvement of CNC machining technology ensures that the application of CNC machining technology can effectively promote the economic development of enterprises. In order to comprehensively improve the application of CNC machining technology, it is necessary for industrial enterprises to pay attention to the importance of improving CNC machining technology and increase investment in the research and development of CNC machining technology, so as to ensure that the improvement of CNC machining technology can achieve corresponding results. The enterprise has achieved the application improvement of CNC machining technology, which can improve the production quality of titanium alloy precision castings to the greatest extent, and can also speed up the production efficiency on the basis of cost saving. With the continuous optimization and improvement of CNC machining technology, it can also improve the application degree of CNC machining technology and solve the problems and difficulties in the application process of CNC machining technology, so as to further realize the production and processing of some larger and more complex titanium alloy precision castings.
3.2 Select the most appropriate machine to ensure the quality of CNC machining
There are many types of machine tools that can be selected when constructing a CNC machining production line for large titanium alloy precision castings. Among them, EDM machine tools and milling machine tools are the most widely used types. In order to ensure the actual production efficiency and product quality of the production line and reduce the number of subsequent adjustments and maintenance, it is necessary to pay full attention to the selection of CNC machine tools. Because there are many types of large titanium alloy precision castings, and the structure of castings is often complex, it is difficult to process. Therefore, the corresponding production processes of different types of titanium alloy precision castings also have great differences. In order to accurately and high-quality produce titanium alloy precision castings in the actual production process, and to compress the production cost as much as possible while completing the actual production needs, it is necessary to comprehensively classify the types of large titanium alloy precision castings to be produced to ensure the actual production effect. Due to the classification of titanium alloy precision castings, it is also necessary to select the corresponding CNC machine tools when designing the production line. Only by selecting the most suitable CNC machine tool can we ensure that the CNC machining process can be carried out smoothly and stably, so as to ensure the actual production efficiency and basic production quality of large titanium alloy precision castings.
3.3 Improve the machining accuracy of titanium alloy precision castings, so as to effectively improve the machining quality.
Traditional castings processing method, in the actual production practice gradually exposed its existing problems and insufficient c traditional casting processing method, cost processing production time is longer, but the finished casting products often quality is very unstable, it is easy to appear a large number of low quality products, waste a large number of raw material resources and due to the limitation of production process, the casting product also has not enough fine shortcomings, can not meet the demand of precision casting processing. In today's people for the requirement of industrial production gradually improve under the background, the traditional casting process cannot meet the production demand, cause, the overall development of casting production enterprises is affected by serious, even lead to it, cannot effective use of titanium alloy, such as raw materials, cause its market competition ability into a, step weakened: in the process of science and technology is widely used to all walks of life, numerical control, processing technology in the application of large titanium alloy precision casting processing, has obtained very, good effect, with the deepening of CNC processing technology application, the traditional casting process is gradually eliminated. Is in the industrial market innovation at the same time, in order to ensure that the numerical control processing technology has enough market vitality, also need to nc machining, optimization reform, including for titanium alloy precision casting processing quality and precision, is the main challenge facing large titanium alloy precision casting fine degree and quality, is the direct embodiment of production processing technology, only pay attention to the quality of the finished products and fine, thus targeted optimization of numerical control processing technology, can truly realize the overall progress of industrial industry.
3.4 Deeply optimize the production line of precision castings and strengthen the application effect of CNC machining technology
The deep optimization of CNC machining production line is a direct method to ensure the production and processing efficiency of CNC machining production line and strengthen the application effect of CNC machining technology. Because the application effect of numerical control technology is greatly affected by the programming level of numerical control processing technology, in order to deeply optimize the numerical control processing production line and improve the processing quality of large titanium alloy castings, programmers need to modify and adjust the numerical control programming program according to the actual needs. Programmers need to fully consider the three main factors of processing sequence, processing time and processing quality, so that the whole production line can complete the production and processing work in accordance with the relevant instructions, so as to effectively improve the application effect of CNC machining technology and improve the production and processing flow of large titanium alloy castings.
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4 Conclusion
On the whole, the application of numerical control technology has promoted the modernization of China 's industrial field, and the continuous improvement of the overall level of China 's industry has also put forward more stringent requirements for the further optimization of numerical control technology. China has always been a powerful country in the field of mechanical manufacturing. In the field of modern processing and manufacturing, in order to achieve efficient development on the basis of ensuring the quality of finished products, it is necessary to fully apply the numerical control processing technology. Relevant industrial enterprises should appropriately strengthen the research on NC machining technology, comprehensively improve the whole enterprise 's cognition of NC machining technology, and realize the overall improvement of technical ability. At the same time, industrial enterprises also need to conduct in-depth research on raw materials for production, especially pay attention to the research on the processing flow of titanium alloy materials, and fundamentally solve the deformation problems of titanium alloy large-scale precision castings in the production process as much as possible. It is difficult to control, the casting structure is complex, and the machining accuracy is high.
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