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金刚石涂层大幅延长刀具使用寿命

发布时间:2013-08-08

  航空工业的成就是建立在各专业公司之间通力合作的基础之上的:在加工复合纤维材料时,位于Stade和Hamburg的空客公司由于采用了与多家公司合作研发涂有金刚石涂层的整体硬质金属钻头,从而节省了时间和金钱。

  在飞机制造业中,较低的制造成本就如同安全性高、使用寿命长以及燃耗小等特点一样,都是在全球竞争中取得领先的决定性因素,因此设计人员都愿意考虑采用轻型材料,如新型的铝合金材料(AlSi)和碳化纤维加强型塑料。CFK在结构重量上大约占了新型A380客机的22%(图1)。根据使用目的选择工具

  这种材料对切削加工的要求很高。特别是在Hamburg的A380总装车间里,对CFK、铝和钛等混合材料进行钻孔时,刀具的磨损程度尤其严重。为了能满足切削任务对刀具寿命和质量的要求,必须对刀具进行优化。对此,空客公司联系了工具制造厂商Klenk公司。该公司在一个由Hamburg-Harburg技术大学主持的共同研发项目中,与瑞士硬质金属专业厂家Extramet公司和涂层专业厂家Cemecon公司共同研发出了相适应的刀具。这些刀具在基材、几何形状和涂层方面完全符合使用领域的要求。

  A380设有两层。底层天花板的横梁为CFK材质,必须与支撑结构即铝隔板相结合使用。在对这种复合材料进行切削时,如果钻头没有涂层,其寿命则只能钻出90个孔。在镀上一种相应的CC-Dia-Fiberspeed涂层材料之后,在最初的切削试验中就达到了500个钻孔,而钻头或涂层仍然完好。

  采用金刚石涂层的刀具,在这种应用场合其使用寿命可以延长大约45%。通过在硬质金属上优化涂层的附着机理,就可以使钻头的圆周磨损程度大大降低。由于更换时间变短,工具购置费用节约潜力大,因此在生产效率得到极大提高的同时,制造质量也相应提高很多。哪个牌子好卸妆薰衣草精油去疤痕推荐丰胸推荐护肤花水什么牌子好眼影舒缓镇定什么牌子好

  空客军用A400M型飞机的机翼需要加工最大达10mm直径的铆钉孔,用以对纵梁与机翼表层进行连接。纵梁为纵向轻型筋条结构,可以提高大而扁平部件的刚性。纵梁和机翼表层均采用CFK材质,应在一个加工步骤中一起被钻孔,因此避免外部材料层脱层或剥落就显得极为重要。使用未镀层或用PVD加层的钻头时,无法达到空客公司所要求的公差等级为H8的高精度。

  CC-Dia系列Diamant-Multilayer金刚石多涂层技术非常有效:通过CFK Paroli涂层钻头,可以消除剧烈的磨损现象。此外,金刚石也非常耐受化学侵蚀,这也可以避免工件材料的吸附现象。

  延长工具使用寿命提高生产效率

  然而,在飞机制造中不是只有Sandwich很重要,铝材也始终是一种热门的材料。驾驶舱和机身与承载面之间的过渡段仍然需要整体铝质部件。空客的目标是要提高这些部位的稳定性,为此,空客公司接洽了工具制造厂商Jabro公司。为了提高铣削流程的稳定性和工具的使用寿命以及生产效率,Jabro公司与空客Meaulte公司的生产部门进行了非常紧密的合作。

  共同研发出来的刀具被用于空客公司的生产中。在最初的测试之后得出结论:铝材吸附的结果是使得力矩在铣削过程中不断变大。这种吸附会影响到被切削材料的结构,从而会对工具的使用寿命带来不良的影响。因此做出了如下的要求:刀具的使用寿命应延长一倍,以便提高生产效率,并达到稳定的生产流程。

  Cemecon公司为Seco Jabro-VHM铣刀研发出特别适宜的Mega-T涂层技术。对刀具的预处理也做了详尽的考察,并开发出一种可以降低铝材吸附程度的工艺。同样,空客公司车间内部的刀具传送作业也得到了优化,以达到生产流程的最高精确度。



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J-Crown curve decoration knives

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