Peilu Li

Milling process enhancement for an aluminium alloy component with a large bore and variable wall thickness for incomplete circular surfaces, research on the optimization of milling process parameters based on machining stability and machining deformation control was carried out. Analysis of the formation mechanism of the regeneration effect caused by casting defects in cast aluminium parts, the stability lobe diagrams are plotted by the zero-order frequency domain analysis method, and the effects of radial depth of cut, cis-reverse milling and the dynamics parameters of the milling system on the boundary range of the stability lobe diagram were investigated. By orthogonal simulation analysis of milling deformation, determine the primary and secondary relationship between the influence of each process parameter on the machining deformation and the optimal combination of each process parameter in the test range. The results show that in the milling process, reducing the radial depth of cut, using a more rigid milling cutter and reverse milling can all be effective in improving the stability of the process; The significant influence of process parameters on the amount of machining distortion is: radial depth of cut > feed rate > cutter’s speed, the optimal combination of process parameters is: cutter’s speed 600 r/min, radial depth of cut 0.2 mm, feed rate 150 mm/min.The process parameters are used for machining verification, the surface roughness of the annular hole was improved from 6.3 to 3.2 before the optimization, and the coaxiality was improved from 0.12mm to 0.05mm before the optimization. The results show that Optimised milling process parameters improve part quality.

According to the acousto elastic effect, the residual stress on the surface of the rail can be evaluated by measuring the change in the propagation velocity of ultrasonic waves, such as longitudinal critically refracted (LCR) waves on the surface of the rail. The LCR wave signal is often polluted by a variety of noise sources, coupled with the influence of the poor surface condition of the inspected component, which greatly reduces the detectability and online measurement ability of the LCR wave signal. This paper proposes the application of the lifting scheme wavelet packet transform (LSWPT) denoising method to solve the noise suppression problem of LCR wave signal. The traditional wavelet transform (WT), wavelet packet transform (WPT), as well as the lifting scheme wavelet transform (LSWT) and lifting scheme wavelet packet transform are compared and analyzed in the soft thresholding and hard thresholding processing of denoising ability and efficiency of the noisy LCR wave signal. The experimental results show that the LSWPT method has the characteristics of fast calculation speed and a good denoising effect, and it is an efficient method of denoising signals for on-line ultrasonic measurement of residual stress on the rail surface.

Aiming at the problem that the dimension error is difficult to control after wire cutting of TC4 alloy parts, a scheme for measuring the residual stress of TC4 alloy seeker based on ultrasonic critical refraction longitudinal wave method is proposed. The residual stress distribution after wire cutting and the distribution of secondary wire cutting after stress release were measured respectively. Combined with three-coordinate measuring error, the deformation law under different residual stress distribution is analyzed. The results show that the deformation error of seeker can be controlled by reducing the amplitude of residual tensile stress introduced by wire cutting.