The processing technology
The non-traditional machining technology is a method of directly processing various forms of energy, including electric, light, chemical, electrochemical, acoustic, thermal, and mechanical energy.
- Non-traditional machining tools do not come into direct contact with the parts being processed, and are not affected by the strength and hardness of the workpiece during processing. This allows for the processing of ultra-hard brittle materials and precision micro-parts, even if the tool material has a lower hardness than the workpiece material.
- Materials are removed by using electricity, chemistry, electrochemistry, sound, light, heat, etc. instead of relying on mechanical energy.
- The processing mechanism differs from conventional metal cutting as it does not produce macro chips or result in strong elastic and plastic deformation. This results in very low surface roughness and significantly reduced residual stress, cold work hardening, and heat influence compared to conventional metal cutting.
- The processing energy is easily controllable and convertible, providing a wide processing range and strong adaptability.
The future development of non-traditional machining technology should focus on the following:
(1) Improving the quality of high-energy beam sources to achieve high power and reliability.
(2) Developing high-energy beam processing equipment towards multi-functionality, precision, and intelligence, with the aim of standardization, serialization, and modularization, and expanding its scope of application to include composite processing.
(3) Advancing the engineering and industrialization of new technologies, processes, and equipment for high-energy beam processing.
To reach these development goals, technical research must be conducted on the following processing techniques:
Research on high-efficiency laser processing technology for creating gas film holes in turbine blades without causing recast layers or microcracks;
Investigation of laser welding techniques for aluminum alloys, super steel, titanium alloys, and components made from dissimilar materials, as well as for large, curved parts in spacious areas;
Study of 3D laser cutting process specifications and the control of surface quality and online measurement technology;
Investigation of laser shock technology for enhancing the fatigue resistance of critical components such as high-temperature alloys and aluminum alloys;
Research into laser rapid prototyping technology;
Investigation of high-power laser cladding for ceramic coating processes and the microstructure and properties of the coatings.
(2) Electron beam processing technology
Technical Investigation of a 150 kV, 15 kW High-Voltage Electron Gun and High-Voltage Power Supply;
Investigation of Electron Beam Physical Vapor Deposition Technology;
Investigation and Quality Evaluation of Electron Beam Welding Technology for Large, Thick, and Variable Cross-Section Titanium Alloys;
Investigation and Engineering of the Electron Beam Curing Process for Typical Composite Aircraft Components;
Investigation of Multi-functional Electron Beam Processing Technology.
(3) Ion beam and plasma processing technology
Conduct research on “conformal” ion implantation and hybrid deposition techniques for complex parts with the aim of obtaining high-density plasma methods.
Investigate adaptive control of the spatial structure welding process parameters and develop an automatic tracking system for the weld seam. Additionally, research deformation control technology in plasma arc welding.
Conduct research on the structure, process, and engineering of plasma-sprayed ceramic thermal barrier coatings.
Investigate laminar-turbulent automatic conversion technology and axial powder feeding, as well as three-dimensional spraying technology.
Develop a laminar plasma spray system and research its spraying technology.
(4) Electrical processing technology
Research on Deep Small Hole Electro-Liquid Beam Processing Technology of High Quality;
Research on High-Efficiency, High-Quality Photoelectrochemical Hole Processing Technology;
Research on Multi-Axis, Multi-Channel EDM Machining of Group Holes and Special-Shaped Holes;
Investigation of High-Capacity (5000A and Above) Precision Electrolytic Processing Technology;
Study of Electrolysis-Electric Spark Composite Processing Technology.
The Focus of the Above Technology Studies is: