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[Scientific and technological achievements] Electromagnetic strengthening technology
Technical background
With the vigorous development of aviation, aerospace, nuclear power, marine equipment, and automobile manufacturing, especially the implementation of the national aerospace deep-sea strategy, higher requirements have been put forward for the machining and manufacturing of high-end equipment. In order to effectively improve the surface integrity and processing efficiency of equipment manufacturing, and reduce the manufacturing cost, the research and application of electromagnetic strengthening technology of high-performance machining tools has been carried out by the Institute of electromagnetic strengthening technology of high-performance machining tools.
This technical achievement has outstanding effects, wide application, good integration with enterprises, and environmental friendliness. It has promoted the technological progress of the industry and produced significant social and economic benefits. The expert evaluation organized by the Science and Technology Development Center of the Ministry of Education unanimously agreed: "The project results are innovative, the technology accumulation is deep, and the overall technology has reached the international advanced level. The method of measuring the electromagnetic enhancement process is at the international leading level and has broad application prospects". With such a powerful technology, let's first understand its technical characteristics.
Characteristics of electromagnetic strengthening technology
1. Under normal temperature conditions, do not change the size of the morphology;
2. Suitable for final tool product optimization, significantly improve tool life and stability, and improve the integrity of the machined surface;
3. The technology has a wide range of applications, suitable for high-performance tools such as coated cemented carbide, cermet, cubic boron nitride (CBN), diamond (PCD), etc;
Special equipment for electromagnetic strengthening
science and technology research and development
Generally speaking, the microscopic defects of materials mainly include dislocations, stacking faults, twins and so on. The specific electromagnetic field has a significant "de-binding" effect on the microscopic defects of crystal materials, which reduces the initiation and propagation of cracks, and then improves the wear resistance of materials.
■ Change of microscopic defects
TC4 titanium alloy was used to study the influence of material dislocation distribution. The results show that the dislocation density distribution of TC4 titanium alloy changes significantly after electromagnetic treatment, the high dislocation density region disappears, and the overall dislocation distribution shows a trend of homogenization.
KAM nephogram of micro-area before and after electromagnetic treatment
(A) Before electromagnetic treatment; (B) After electromagnetic treatment;(c)(d) Enlargement of the box area in (a)(B) respectively
■ Study on the mechanism of "de-binding"
The mechanism of doped monocrystalline silicon is studied, and the view point is put forward that the electron pair in the single-line excited state at the specific electromagnetic field promotes the defect to the three-line state, and then the microscopic defect of the crystal material has a significant "stripping" effect.
Effect of electromagnetic treatment and heat treatment on the state of single crystal silicon vacancy group
(a) first electromagnetic treatment followed by heat treatment; (B) first heat treatment followed by electromagnetic treatment
Industrial Application and Technical Advantage
With the development of high-speed cutting and high-feed cutting technology, the modern cutting industry has entered a new stage of modern high-speed processing with high-speed, high-precision and high-efficiency as the core goal.
Tool electromagnetic treatment technology is the use of electromagnetic field on high-speed steel, coated carbide, cubic boron nitride (CBN), diamond (PCD) and other tools for electromagnetic treatment, change the mechanical properties of materials and tool cutting mechanism, thereby improving tool cutting performance, increase tool wear resistance and extend tool life, ensure processing quality, improve production efficiency.
Electromagnetic strengthening technology has been successfully applied to 18 key enterprises in aviation manufacturing, energy equipment, construction machinery, automobile manufacturing and other industries. 61 tool brands have been processed, with an annual processing tool value of more than 14 million, which can improve the tool life by 30% ~ 200%, bringing millions of yuan of cost reduction benefits to enterprises.
aviation manufacturing industry
In the field of aviation manufacturing, it has cooperated with aviation industry Chengdu Aircraft Industry (Group) Co., Ltd., China Aviation Development Harbin Dongan Engine Co., Ltd., Yingpu Aviation Parts (Wuxi) Co., Ltd. and other enterprises to carry out aviation structural parts (titanium alloy, High temperature alloy) processing application.
In Chengfei CNC Center for Walter, Shangao, Golden Heron and other tools of electromagnetic reinforcement application. Taking Walter square shoulder milling cutter as an example, its processing product is a certain type of titanium alloy structure. The tool model is ADMT120430R-F56 WSM35, and the processing parameters are: rotation speed (S)1294r/min, feed rate (F)168 mm/min, cutting depth (ap)3mm, cutting width (AE) 3mm, plus
The work method is linear milling.
From the tool wear curve, the tool is in a stable wear cycle longer, the tool wear resistance is improved, the service life is increased by more than 30%, and the tool stability is improved, which effectively improves the production efficiency of aviation manufacturing.
Engineering Machinery
In terms of construction machinery and equipment, it has cooperated with Caterpillar (Suzhou) Co., Ltd., Jiangsu Hengli Hydraulic Co., Ltd., Toyo Electromechanical (Jiangyin) Co., Ltd., Xuzhou Shitong Heavy Industry Machinery Manufacturing Co., Ltd. and other enterprises to carry out steel parts, Stainless steel parts and other materials processing tool technology application. At present, many types of tools such as turning tools, slotting cutters, milling cutters, taps, convertible drills, etc. have been processed in batches, with an average monthly processing capacity of more than 10000 pieces/piece.
Construction machinery parts processing
It is applied in the processing center of small bream (Changzhou) machinery co., ltd. the processing product is a certain type of reducer housing (casting), and the tool used is the imported tool iska IC908 series convertible drill bit. Under the premise of ensuring the stability of production conditions, the test and application of the service life and wear performance of the initial drill bit and the electromagnetic treatment drill bit are carried out.
Topography of Convertible Drill and Reducer Casing
Analysis of wear morphology and wear volume of initial drill bit and electromagnetic treatment drill bit
On this basis, the processing application of multi-model convertible drill bit technology was carried out. The statistical results show that for different specifications of drill bits, after electromagnetic strengthening treatment, the service life of the tool is improved by about 30%, the technical adaptability is better, and the cost of the tool is saved more than 100,000 yuan per year for the enterprise.
Automobile Manufacturing
In terms of automobile manufacturing, it has cooperated with Tianjin Yinbaoshan New Technology Co., Ltd., Getrag (Jiangxi) Transmission System Co., Ltd., Wuxi Yingbei Precision Bearing Co., Ltd. and other enterprises to carry out coated cemented carbide, ceramic blades, and cubic boron nitride (CBN), diamond (PCD) and other tools batch application. After electromagnetic treatment, the cutting mechanism of the tool changes, reducing the friction coefficient and tool wear in the machining process, and the surface quality of the parts is higher.
The cubic boron nitride (CBN) inserts of the carburized gear production line of Getrag (Jiangxi) Transmission System Co., Ltd. are used in batch applications to track the roughness of the inner hole of the gear in the production line to characterize the surface quality of the parts. After processing the CBN blade, the inner hole roughness of the part is smaller, and the curve is more gentle, and the surface quality of the part is more stable. The technology application project won the second prize of the 2019 Jiangling Group Science and Technology Progress Award and was recognized by customers.
Cubic boron nitride blade and carburized gear parts (inner hole processing)
Part Hole Roughness History Curve
Tool production enterprises and agents cooperation
On the basis of the existing end customers, we have carried out cooperation and promotion with Xiamen Jinlu Special Alloy Co., Ltd., Antima (Suzhou) Precision Tools Co., Ltd. and other tool manufacturers and agents. At present, it has been applied in the fields of high-efficiency cutting of titanium alloy, high-temperature alloy processing, stainless steel processing and so on. Looking forward to your consultation and cooperation.
Technical docking and business negotiation
Contact: Wu Yao
Contact number: 15600646665 (same as WeChat)
E-mail: wuyao@tsinghua-tj.org
Source | Tool & Bearing Electromagnetic Strengthening Technology Research Institute
Editor | Wang Xiao
The final interpretation of the above related technologies belongs to the Tool & Bearing Electromagnetic Strengthening Technology Institute.
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Tianjin High-end Equipment Research Institute, Tsinghua University, Copyright
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