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Since the beginning of the twentieth century, manufacturing technology, especially advanced manufacturing technology, has continued to develop. As an important part of advanced manufacturing technology, the role of special processing in manufacturing has become increasingly important. He solved the problems encountered in traditional processing methods and has its own unique characteristics. It has become an indispensable important processing method and means for modern industry.
What is special processing?
Special processing was developed in the 1940s. Due to the development of materials science, high-tech and fierce market competition, and the urgent need for cutting-edge national defense and scientific research, not only the new product replacement is accelerating, but also the product requirements are highly intensive. Weight ratio and performance price ratio, and is developing towards high speed, high precision, high reliability, corrosion resistance, high temperature and high pressure, high power, and size. To this end, a large number of precision mechanical parts with new materials, new structures and complex shapes have emerged, and a series of new problems that need to be solved urgently have been proposed for the mechanical manufacturing industry. For example, the processing of various difficult-to-cut materials; various structural shapes are complex, the size is small or extra large, the processing of precision parts; the rigidity of thin walls, elastic components, and the processing of special parts. In this regard, the use of traditional processing methods is very difficult, and even impossible to process. Therefore, on the one hand, people improve the cutting state and improve the cutting process by studying the tools and tool materials for efficient machining, automatically optimizing cutting parameters, improving tool reliability and online tool monitoring system, developing new cutting fluids, and developing new automatic machine tools. Level, and solve some problems; on the other hand, it breaks through the constraints of traditional processing methods, constantly explores and seeks new processing methods, so a special processing that is essentially different from traditional processing comes into being and continues to be obtained. development of. Later, due to the further development of novel manufacturing techniques, people defined the special processing in a broad sense, that is, the energy, such as electric, magnetic, acoustic, optical, chemical, or a combination thereof, was applied to the processed portion of the workpiece, thereby realizing material removal and deformation. Non-traditional processing methods such as changing performance or being plated are collectively referred to as special processing.Two special processing features
1. No mechanical energy, no mechanical properties of the object to be processed, some processing methods, such as laser processing, EDM, plasma arc processing, electrochemical processing, etc., are the use of thermal energy, chemical energy, electrochemical energy, etc. The hardness of the workpiece is independent of mechanical properties, so it can process a variety of hard and soft, brittle, heat sensitive, corrosion resistant, high melting point, high strength, special properties of metal and non-metallic materials.2. Non-contact machining does not necessarily require tools. Some use tools, but they do not touch the workpiece. Therefore, the workpiece does not bear a large force, and the hardness of the tool can be lower than the hardness of the workpiece, so the components with extremely low rigidity and elastic components are made. Processed.
3. Micro-machining, the surface quality of the workpiece is high, and some special processing, such as ultrasonic, electrochemistry, water jet, abrasive flow, etc., the machining allowance is fine, so it can not only process small holes or slits, but also obtain High precision, extremely low roughness machined surface.4. There is no mechanical strain in processing or large area thermal strain, which can obtain lower surface roughness, and its thermal stress, residual stress, cold work hardening, etc. are relatively small, and dimensional stability is good.
5. Two or more different types of energy can be combined with each other to form a new composite processing, and the comprehensive processing effect is obvious, and is convenient for popularization and use.6. Special processing has a positive impact on simplifying the processing technology, changing the design of new products and the structural and processability of parts.
Classification of three special processingLike other advanced manufacturing technologies, special processing is being researched, developed, and applied, with good development potential and application prospects. Various commonly used special processing methods are listed according to the source and action form of processing energy.
processing methods | Main energy form | Form of action | |
Electric discharge machining | Electric spark forming | Electricity, heat | Melting, gasification |
Wire EDM | Electricity, heat | Melting, gasification | |
Electrochemical processing | Electrolytic processing | Electrochemical energy | Ion transfer |
Electroforming | Electrochemical energy | Ion transfer | |
Coating process | Electrochemical energy | Ion transfer | |
High energy beam processing | Laser beam processing | Light, heat | Melting, gasification |
Electron beam processing | Electricity, heat | Melting, gasification | |
Ion beam processing | Electrical and mechanical energy | Cut-off | |
Plasma arc processing | Electricity, heat | Melting, gasification | |
Material etching | Ultrasonic machining | Acoustic and mechanical energy | Cut-off |
Abrasive flow processing | Mechanical energy | Cut-off | |
Liquid jet processing | Mechanical energy | Cut-off | |
Chemical processing | Chemical milling | chemical energy | corrosion |
Photographic processing | Chemistry, light energy | corrosion | |
Lithography processing | Light, chemical energy | Photochemistry, corrosion | |
Photoelectric plating | Light, chemical energy | Photochemistry, corrosion | |
Etching process | chemical energy | corrosion | |
Bonding | chemical energy | Chemical bond | |
Explosive processing | Chemical energy, mechanical energy | explosion | |
Forming processing | Powder metallurgy | Thermal energy, mechanical energy | Hot press forming |
Superplastic forming | Mechanical energy | Superplasticity | |
Rapid forming | Thermal energy, mechanical energy | Hot melt forming | |
Compound processing | Electrochemical arc machining | Electrochemical energy | Melting, gasification corrosion |
Electrolytic EDM mechanical grinding | Electricity, heat | Ion transfer, melting, cutting | |
Electrochemical corrosion processing | Electrochemical energy, thermal energy | Melting, gasification corrosion | |
Ultrasonic discharge machining | Sound, heat, electric energy | Melting, etching | |
Composite electrolytic processing | Electrochemical, mechanical energy | Cut-off | |
Compound cutting | Mechanical, acoustic, magnetic energy | Cutting | |
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