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Toyota Prado four-wheel drive system
Toyota Prado (PRADO) Toyota Land Cruiser family's latest SUV. The new development of the next-generation SUV, equipped with Toyota's new 4.0LV6 engine emissions meet Euro Ⅲ standard. Prado (PRADO) advanced engine provides strong power output, together with the sturdy frame and enhanced suspension system so bumpy road to become comfortable and smooth. As a sport utility vehicle, four-wheel drive system can be described as a top priority. This article will introduce you to focus Prado (PRADO) equipped with full-time four-wheel drive system
For ordinary bevel gear differentials, whether inter-wheel differential or intermediate differential, because the planetary gear speed difference in the absorption due to internal friction generated by the rotation is very small, if not to limit it or lock only, if one side (or a shaft) wheel slip, the other wheels (or axles) is also the driving force is limited to the side of the wheel slip (or axis) of the driving force is equal to the tire can not be fully grip, affect the car's off-road. Prado (PRADO) chassis system uses a full-time drive mode, the layout of the three differentials: front, rear differential bevel gear differentials using ordinary, non-differential limiting and locking device, left and right both sides of the wheel slip through the TRC / VSC braking system to limit; intermediate differential use childcare Sen (TORSEN) T-3-type limited-slip differential. Domestic FAW Toyota Prado (PRADO) using 4BM actuator, can be achieved electronically controlled differential lock.
Full-time four-wheel drive system, the basic structure
Toyota Prado(PRADO)four-wheel drive system consists of the mechanical part of the transmission, actuator (available electronically controlled locking differential), front and rear drive shaft and front and rear differential sand other components.
Theel ectronically controlled four-wheel drive in part by the brake control ECU, the engine ECU, inter mediate differential locking button, parking and neutral position switch, 4WD control ECU and splitter electric actuator sand other components .Splitter electric actuator so perate according to the driver's wishes(center differential lock button), brake status, state of the engine operating speed, transmission gear status signal splitter for the differential lock stop control. The purpose of doing so is to facilitate the driver's operation, to ensure the transmission of switching actuator accurately and efficiently, avoid mechanical damage caused by misuse.
Splitter electric actuators
FAW Toyota Prado (PRADO) engine model 1GR-FE, transmission model A750F, its sub-actuators using improved VF4BM. Shown in Figure 2, actuator has two gear L and H, the transmission ratios of 2.566 and 1.000, L, H gear manually by the driver. According to road conditions and the driver to switch the "intermediate differential locking button" to carry on the differential lock, thus enabling H4F-H4L-L4F-L4L shift mode. H4F and L4F splitter for the corresponding high and low gear differentials "F" (free) mode, H4L and L4L was "L" (lock) mode. Other types of sub-actuator shown in Table 1, wherein VF2A splitter 2700 models used in the Prado, TORSENLSD the optional component.
Coming from the power transmission through the splitter and a subtransmission L or H gear spread differential gear casing, and then by the differential transmission mechanism within the power to the front, rear axle, 4WD control ECU for the splitter electric actuator control, drive "middle differential lock fork shaft" to achieve the intermediate differential lock switch.
TORSENLSD slip differential structure
TORSENLSD structure mainly by the differential housing, the planetary gear carrier, the planetary gear, a sun gear, a ring gear engaging gear, the sun gear wheel engaging the clutch disc, and four other components. The structure has eight planets and the sun gear and the ring gear external teeth meshing with each other, their mutual tooth meshing gears are TORSENT-3 type. When the ring gear and the sun gear of the speed ranges when (a drive shaft with slip tendency), will be forced to produce planetary rotation movement, this movement will lead to rotation with the ring gear or the sun gear relative axial movement. Axial movement of the pressure within the device installed in the clutch pressure plate, resulting in internal friction, thus limiting the relative movement, also limits the movement of the drive shaft to slip, and increase the torque of the drive shaft does not slip; sun wheel engaging with the sun gear wheel pair with each other, so that the sun wheel to the front coming from the PTO shaft. And put the ring gear engaging the ring gear teeth to the rear PTO shaft, thus engaging the teeth actually used for transmission of power transmission gear. As long as the front and rear wheels due to the adhesion surface due to changes in the torque changes, the differential will immediately produce than ordinary differential (non-limiting type) to a much larger internal friction torque. This method is also called differential limit torque-sensitive type.
Different driving conditions TORSENLSD torque distribution
The splitter switch to H4F or L4F mode, the differential is in "free mode", TORSENLSD have the following four operating states.
1 front axle rear axle speed equal to speed
When the car is driving in a good straight road, the front and rear wheel speed close to equal, that the sun wheel and the ring gear is equal to the angular velocity, the power of the transmission line shown in Figure 6. Shown in Figure 7, the sun wheel and the ring gear speed is equal, the planet gears not rotation movement, the internal friction differential is 0, the radius of the sun wheel and the ring gear ratio of 2:3, the torque of the front axle and the rear axle ratio of 2:3. Normal driving, the rear axle 60% of the torque obtained, to obtain 40% of the torque of the front axle. This torque distribution and quality of the car distribution corresponds to favor the use of the rear axle when the vehicle speed is greater than the front axle load cases, enhance vehicle tire grip to increase stability of the vehicle.
2 speed rear axle front axle speed is greater than
When the steering wheel or because of slippery roads lead to slip, the vehicle speed is greater than the front axle rear axle appears the situation. Ring sun gear wheel speed is greater than speed, relative movement between the forced rotation of the planetary gears. But because it is the ring gear and the sun gear meshing with each other, meshing with great friction profile angle, and the planetary gear carrier and it will produce friction between, so the rotation of the planetary gear over the friction force by , squeeze the 4th clutch disc. On the other hand, the ring gear is axially leftward movement, squeezing the 1st clutch disc. On the 4th friction clutch plate, limiting the high-speed continues to increase the rotational speed of the sun gear, the No. 1 of the friction clutch plate, put the power differential housing directly transmitted to the ring gear. From the above, the planetary gear and the clutch plate friction autobiography constitutes the friction torque of internal friction, thereby increasing the driving force of the rear axle. Before the rear axle torque distribution ratio can be up to 29:71, thus reducing the front axle torque, putting more driving force distribution to the rear axle attachment good condition. When the vehicle to achieve this torque distribution, the steering axle drive torque reduction, increased lateral adhesion, reduces steering skidding tendency operational stability has been improved, but also improve the car on slippery roads when through sex.
3 speed rear axle front axle speed is less than
When the ring gear speed is greater than the sun wheel speed, then the planetary gear also produces rotation, rotation time with the ring gear, the sun gear and the tooth will produce friction between the frame; while planetary gear axially to the left, the ring gear and the sun gear respectively, to the left, to the right to make axial movement, still squeezing the 1st ring gear clutch plate, squeeze the 2nd planetary gear clutch disc, sun wheel squeezing the 4th clutch disc, so high-speed rear axle by the 1st and 2, the friction clutch constraints while powered by the planetary gear carrier through the friction clutch plate 4 directly to the sun wheel, increasing the output torque of the front axle. By the internal friction of the differential 1, 2, 4, rotation of the planetary gear friction components, the front, the rear axle reaches the maximum torque distribution ratio 53:47.
4 locking center differential
If a smaller front wheel traction, slip trend emerged, automatically limits its slip differential, front-wheel drive is automatically reduced to 29%. If the wheel continues to decrease adhesion, but this time the front wheel drive force can be further reduced, not the rear axle slip torque is assigned to only 71%, at this time, the driver should locking differential, which kind of situation generally occurs in the morass of extraordinary bad road. If the front wheels off the ground (floating), the driving force of the wheel to 0, then if not locking differential, rear axle can only be assigned to 71% of the maximum driving force, but if locking the differential, rear axle can be assigned to 100% of the drive force.
豐田普拉多全時(shí)四驅(qū)系統(tǒng)
豐田普拉多（PRADO）是豐田陸地巡洋艦系列中的最新款SUV。這款全新開(kāi)發(fā)的新一代SUV，配備了豐田全新4.0LV6發(fā)動(dòng)機(jī)，排放達(dá)到歐Ⅲ標(biāo)準(zhǔn)。普拉多（PRADO）先進(jìn)的發(fā)動(dòng)機(jī)提供強(qiáng)勁的動(dòng)力輸出，配以堅(jiān)固的車架以及強(qiáng)化的懸架系統(tǒng)，使坎坷的路途變得舒適順暢。作為一款越野車，四輪驅(qū)動(dòng)系統(tǒng)可謂是重中之重。本文將著重為您介紹普拉多（PRADO）裝備的全時(shí)四驅(qū)系統(tǒng)。
對(duì)于普通的錐形齒輪式差速器，不論是輪間差速器還是中間差速器，由于行星齒輪在吸收轉(zhuǎn)速差時(shí)因自轉(zhuǎn)而產(chǎn)生的內(nèi)摩擦力很小，假如不對(duì)其進(jìn)行限制或鎖止，只要有一側(cè)（或一軸）車輪滑轉(zhuǎn)，則另一車輪（或車軸）的驅(qū)動(dòng)力也會(huì)被限制到與滑轉(zhuǎn)一側(cè)車輪（或一軸）的驅(qū)動(dòng)力相等，不能充分發(fā)揮輪胎的抓地力，影響汽車的越野性。普拉多（PRADO）的底盤系統(tǒng)采用了全時(shí)驅(qū)動(dòng)方式，布置了3個(gè)差速器：前、后差速器采用普通錐形齒輪式差速器，無(wú)差速限制和鎖止裝置，左、右兩側(cè)車輪的滑轉(zhuǎn)通過(guò)TRC/VSC系統(tǒng)以制動(dòng)方式來(lái)限制；中間差速器采用托兒森（TORSEN）T-3型限滑差速器。國(guó)產(chǎn)的一汽豐田普拉多（PRADO）采用4BM分動(dòng)器，可以實(shí)現(xiàn)對(duì)差速器的電控鎖止。
全時(shí)四驅(qū)系統(tǒng)的基本構(gòu)成
豐田普拉多（PRADO）四驅(qū)傳動(dòng)系統(tǒng)的機(jī)械部分主要由變速器、分動(dòng)器（可電控鎖止差速器）、前后傳動(dòng)軸及前后差速器等組成。
四驅(qū)的電控部分由制動(dòng)控制ECU、發(fā)動(dòng)機(jī)ECU、中間差速器鎖止按鈕、駐車及空擋位置開(kāi)關(guān)、4WD控制ECU和分動(dòng)器電控執(zhí)行器等組成。分動(dòng)器電控執(zhí)行器根據(jù)駕駛員的操作意愿（中間差速器鎖止按鈕）、汽車制動(dòng)狀態(tài)、發(fā)動(dòng)機(jī)運(yùn)行轉(zhuǎn)速狀態(tài)、變速器擋位狀態(tài)等信號(hào)對(duì)分動(dòng)器內(nèi)的差速器進(jìn)行鎖止控制。這樣做的目的是為了便于駕駛員操作，確保分動(dòng)器內(nèi)的傳動(dòng)切換準(zhǔn)確有效，避免由于誤操作而造成的機(jī)件損壞。
分動(dòng)器電控執(zhí)行器
一汽豐田普拉多（PRADO）的發(fā)動(dòng)機(jī)型號(hào)為1GR-FE，變速器型號(hào)為A750F，其分動(dòng)器采用經(jīng)過(guò)改進(jìn)的VF4BM。如圖2所示，分動(dòng)器有L和H兩個(gè)擋位，傳動(dòng)比分別為2.566和1.000，L、H擋位由駕駛員手動(dòng)操作。駕駛員根據(jù)路面狀況切換“中間差速器鎖止按鈕”對(duì)差速器進(jìn)行鎖止，因而可實(shí)現(xiàn)H4F-H4L-L4F-L4L的換擋模式。H4F和L4F為分別對(duì)應(yīng)分動(dòng)器高、低擋的差速器“F”（自由）模式，H4L和L4L則為“L”（鎖止）模式。其他類型的分動(dòng)器如表1所示，其中VF2A分動(dòng)器在普拉多2700車型上使用，TORSENLSD為選裝部件。
由變速器傳來(lái)的動(dòng)力經(jīng)分動(dòng)器的副變速L或H齒輪傳到差速器外殼齒輪，再經(jīng)差速器內(nèi)的傳動(dòng)機(jī)構(gòu)把動(dòng)力傳到前、后軸，4WD控制ECU對(duì)分動(dòng)器電控執(zhí)行器進(jìn)行控制，驅(qū)動(dòng)“中間差速器鎖止撥叉軸”實(shí)現(xiàn)中間差速器鎖的切換。
TORSENLSD防滑差速器結(jié)構(gòu)
TORSENLSD的結(jié)構(gòu)，主要由差速器外殼、行星齒輪架、行星齒輪、太陽(yáng)輪、環(huán)形齒輪接合齒、太陽(yáng)輪接合齒及4個(gè)離合器盤等組成。結(jié)構(gòu)中有8個(gè)行星齒輪與環(huán)齒和太陽(yáng)輪齒內(nèi)外相互嚙合，它們之間相互嚙合齒輪的齒形屬于TORSENT-3型。當(dāng)環(huán)齒與太陽(yáng)輪的轉(zhuǎn)速不等時(shí)（某一驅(qū)動(dòng)軸有打滑趨勢(shì)），行星齒輪會(huì)被迫產(chǎn)生自轉(zhuǎn)運(yùn)動(dòng)，這個(gè)自轉(zhuǎn)運(yùn)動(dòng)又會(huì)導(dǎo)致與環(huán)齒或太陽(yáng)輪的軸向相對(duì)運(yùn)動(dòng)。軸向運(yùn)動(dòng)的壓力對(duì)安裝在裝置內(nèi)的離合器盤施加壓力，產(chǎn)生內(nèi)摩擦力，因此限制了相對(duì)運(yùn)動(dòng)，也就限制了打滑的驅(qū)動(dòng)軸的運(yùn)動(dòng)，而增加不打滑的驅(qū)動(dòng)軸的扭矩；太陽(yáng)輪與太陽(yáng)輪接合齒相互配對(duì)，以便把太陽(yáng)輪傳來(lái)的動(dòng)力輸出到前驅(qū)動(dòng)軸。而環(huán)形齒輪接合齒則把環(huán)齒的動(dòng)力輸出到后驅(qū)動(dòng)軸，因此接合齒實(shí)際上是用于傳遞動(dòng)力的過(guò)渡齒輪。只要前、后驅(qū)動(dòng)輪因地面附著力的變化而導(dǎo)致扭矩的變化，差速器會(huì)立即產(chǎn)生比普通差速器（非限制式）要大得多的內(nèi)摩擦扭矩。這種差速器的限制方式也叫扭矩敏感式。
不同行駛狀態(tài)TORSENLSD的扭矩分配
把分動(dòng)器切換到H4F或L4F模式時(shí)，差速器處于“自由模式”，TORSENLSD有如下的4種工作狀態(tài)。
1.前軸轉(zhuǎn)速等于后軸轉(zhuǎn)速
當(dāng)汽車在良好路面直線行駛時(shí)，前輪與后輪的轉(zhuǎn)速接近相等，即太陽(yáng)輪與環(huán)齒的角速度也相等，動(dòng)力的傳動(dòng)路線如圖6所示。如圖7所示，太陽(yáng)輪與環(huán)齒轉(zhuǎn)速相等，行星齒輪不做自轉(zhuǎn)運(yùn)動(dòng)，差速器的內(nèi)摩擦為0，太陽(yáng)輪與環(huán)齒半徑之比為2:3，前軸與后軸的扭矩比為2:3。正常行駛時(shí)，后軸得到60%的扭矩，前軸得到40％的扭矩。這種扭矩分配方式與汽車的質(zhì)量分配相對(duì)應(yīng)，有利于利用車輛加速時(shí)后軸載荷大于前軸的情況下，提升車輛輪胎的抓地力，增加車輛的穩(wěn)定性。
2.前軸轉(zhuǎn)速大于后軸轉(zhuǎn)速
當(dāng)汽車轉(zhuǎn)向或因濕滑路面導(dǎo)致前輪打滑時(shí)，車輛則會(huì)出現(xiàn)前軸轉(zhuǎn)速大于后軸的情況。太陽(yáng)輪轉(zhuǎn)速大于環(huán)齒轉(zhuǎn)速，兩者的相對(duì)運(yùn)動(dòng)使行星齒輪被迫自轉(zhuǎn)。但是由于它與環(huán)齒和太陽(yáng)輪齒相互嚙合，嚙合的齒形角產(chǎn)生很大的摩擦力，同時(shí)它與行星齒輪架之間也會(huì)產(chǎn)生摩擦力，因此行星齒輪的自轉(zhuǎn)受到以上摩擦力的作用，擠壓4號(hào)離合器盤。另一方面，環(huán)齒則沿軸向向左運(yùn)動(dòng)，擠壓1號(hào)離合器盤。4號(hào)離合器盤的摩擦力，限制了高轉(zhuǎn)速的太陽(yáng)輪的轉(zhuǎn)速繼續(xù)增加，1號(hào)離合器盤的摩擦力，則把差速器外殼上的動(dòng)力直接傳遞到環(huán)齒。由上可知，行星齒輪自傳的摩擦力和離合器片的摩擦力構(gòu)成了內(nèi)摩擦力矩，從而增加了后軸的驅(qū)動(dòng)力。前、后軸的扭矩分配比最大可達(dá)到29:71，從而減小前軸的扭矩，把更多的驅(qū)動(dòng)力分配到附著狀況好的后軸。當(dāng)車輛實(shí)現(xiàn)這種扭矩分配后，轉(zhuǎn)向時(shí)前軸驅(qū)動(dòng)扭矩降低，增加了側(cè)向附著力，可減小轉(zhuǎn)向側(cè)滑的趨勢(shì)，操作穩(wěn)定性得到了改善，同時(shí)也提高了汽車在濕滑路面行駛時(shí)的通過(guò)性。
3.前軸轉(zhuǎn)速小于后軸轉(zhuǎn)速
當(dāng)環(huán)齒轉(zhuǎn)速大于太陽(yáng)輪轉(zhuǎn)速，此時(shí)行星齒輪也產(chǎn)生自轉(zhuǎn)，自轉(zhuǎn)時(shí)與環(huán)齒、太陽(yáng)齒和齒架之間會(huì)產(chǎn)生摩擦阻力；同時(shí)行星齒輪沿軸向向左運(yùn)動(dòng)，環(huán)齒和太陽(yáng)輪分別向左、向右做軸向運(yùn)動(dòng)，環(huán)齒仍然擠壓1號(hào)離合器盤，行星齒輪擠壓2號(hào)離合器盤，太陽(yáng)輪擠壓4號(hào)離合器盤，因此，后軸的高轉(zhuǎn)速受到1號(hào)和2號(hào)離合器片摩擦力的限制，同時(shí)動(dòng)力由行星齒輪架通過(guò)4號(hào)離合器盤的摩擦力直接傳遞到太陽(yáng)輪，增加了前軸的輸出扭矩。差速器的內(nèi)摩擦力由1號(hào)、2號(hào)、4號(hào)和行星齒輪自轉(zhuǎn)摩擦力組成，使前、后軸的扭矩分配比最大達(dá)到53:47。
4.中間差速器的鎖止
假如前輪的地面附著力較小，出現(xiàn)了滑轉(zhuǎn)趨勢(shì)，差速器自動(dòng)限制其滑轉(zhuǎn)，前輪驅(qū)動(dòng)力自動(dòng)降低到29％。若前輪附著力繼續(xù)減小，而此時(shí)前輪驅(qū)動(dòng)力不能再降低，未滑轉(zhuǎn)的后軸所分配到的扭矩只能達(dá)到71％，此時(shí)，駕駛員應(yīng)該鎖止差速器，這種情況一般發(fā)生在非凡惡劣的泥沼路面。如前輪離開(kāi)地面（懸空），該車輪的驅(qū)動(dòng)力降為0，此時(shí)假如未鎖止差速器，后軸只能分配到71％的最大驅(qū)動(dòng)力，但假如鎖止了差速器，后軸則可分配到100％的驅(qū)動(dòng)力。
外文資料及譯文
Special processing Generality
Special processing which is also called "non-traditional machining" or "modern processing method", referring to electrical energy, heat energy, light energy, electrochemistry energy, chemical energy, sound energy and mechanical energy, such as special processing methods to remove or add material energy. Special processing technology is mainly described in this article refers to the laser processing technology, electron beam processing technology, ion beam and plasma processing technology and processing technology, etc.
With the development of new type weapons and equipment, the increasingly urgent demand for special processing technology at home and abroad. Both aircraft, missiles, and other combat platforms are required to reduce the structure weight, improve the speed, increased range, reduce fuel consumption, achieve lighter high performance, structure, long service life and good economic affordability. To this end, the weapon system and combat platforms are required to use integral structure, lightweight structure, the new structure, advanced cooling structure and titanium alloys, composite materials, powder materials, intermetallic compounds, such as new materials.
To do this, you need the special processing technology, equipment manufacturing, in order to solve processing problem of using conventional processing methods cannot be achieved, so special processing technology is the main application areas:
Difficult-to-machine materials, such as high strength steel, titanium alloy, heat-resistant stainless steel, composite materials, engineering ceramics, diamond, ruby, hardened glass high hardness, high toughness, high strength, high melting point materials.
Difficult machining parts, such as complex parts 3 d cavity type, hole processing, group of hole and narrow gap, etc.
Low rigidity parts, such as thin walled parts, elastic element and other parts of the processing.
With high energy density beam for welding, cutting, making holes, spraying, surface modification, etching and fine processing.
1. The laser processing technology
Laser processing equipment and processes abroad has developed rapidly, now has 100 kW high power CO 2 laser , kW level high beam quality of Nd: YAG solid laser, some with optical fiber can be transfer, telecommuting. Big power laser processing equipment, high automatic degree and has been widely used CNC control, multi-axis linkage, and is equipped with laser power monitoring, automatic focusing, industrial TV shows and other auxiliary system.
Laser hole of minimum aperture has amounted to 0.002 mm, has succeeded in application of automation system of six coordinate laser hole special equipment for processing, with holes on the combustion chamber, gas turbine engine to achieve to cast layer, the effect of the micro cracks.
Laser cutting is suitable for the made of heat resistant alloy, titanium alloy, composite material parts. Currently BoCai cutting speed can be up to 15 m/min, narrow kerf width, generally between 0.1 ~ 1 mm, heat affected zone is only 10% ~ 20% of the kerf width, maximum cutting thickness of 45 mm, has been widely used in plane three-dimensional skin ship plate, frame, ships and helicopter rotor, engine combustion chamber, etc.
Laser welding thin plate has been quite common, most are employed in the automotive industry, aerospace and instrumentation industries. Laser subtle welding technology has become an aviation electronic equipment, high precision mechanical equipment in the micro encapsulation nodes one important means of micro connection.
Laser surface strengthening, surface remelting, alloying, amorphous processing technology application is more and more widely, laser microfabrication applications in electronics, biology, medical engineering has become an irreplaceable special processing technology.
Laser rapid prototyping technology has expanded from research and development stage to application stage, has shown broad application prospects.
At home in the early 70 s has begun for laser processing applied research, but the development speed is slow. Hole in the laser system, laser heat treatment, welding, etc. Although have a certain application, but the quality is not stable. Has developed a solid laser processing systems with optical fiber transmission, and realize the optical fiber coupling synchronization of the three beams welding and laser welding of quartz watch movements. Completed the laser sintering rapid prototyping principle prototype, and with polyester and epoxy resin sand sintered powder materials, rapid prototyping of typical parts, such as impeller, the gear.
Laser processing technology in the next few years should combine pre-study achievements have been achieved, according to demand, focus on zero defect laser processing of gas membrane pores and control technology of real-time detection, high strength aluminum) (lithium containing aluminum, aluminum and magnesium alloy laser welding technology, laser sintering rapid prototyping technology, powder of metal parts laser precision machining and important component of the research of laser shock processing, etc. Achieve zero defect with holes on the high temperature turbine engine processing, can make the blade service life of 2000 hours; To welding instead of nc machining plane bearing components, as well as welding for riveting of ribbed wall; Realize the important parts of surface strengthening, improve security, reliability, etc., so that advanced laser manufacturing technology play a more important role in military industry.
2. The electron beam processing technology
Electron beam processing technology become more mature in the world, wide application range. Finalize the design production abroad 40 kv ~ 300 kv electron gun (mainly including 60 kv, 150 kv), has been widely used CNC control, multi-axis linkage, a high degree of automation. Electron beam welding has been successfully used in special materials, dissimilar materials, complex space curve, non-uniform welding, etc. Is currently studying weld automatic tracking, wire filling welding, vacuum welding, such as maximum welding penetration of up to 300 mm, deep weld width than those days. Electron beam welding has been used in space shuttle launch vehicle, the main bearing components are large structures such as the combination of welding, as well as the aircraft beam, box, landing gear parts, whole engine rotor shaft, casing, power and other important structures and nuclear power plant pressure vessel manufacturing. Such as the f-22 fighter with advanced electron beam welding, reduce aircraft weight, improve the performance of the machine; "Su - 27" and other series of large bearing components, such as the gear, the load bearing frame, adopts high voltage electron beam welding technology.
Domestic various types of aircraft and engines and a variety of models of the missile shell, oil tank, the exhaust structures have been adopted the electron beam welding. Therefore, the application of electron beam welding technology is more and more widely, the demand for electron beam welding equipment is becoming more and more big.
Electron beam welder abroad to Germany, the United States, France, Ukraine, etc, have reached the engineering production. Is characterized by variable frequency power supply, the volume of equipment, noise, and high pressure performance is greatly improved; In terms of control system, using advanced computer technology, adopts the advanced CNC and PLC technology, make the control more reliable, equipment operation more simple and intuitive.
Vacuum electron beam physical vapor deposition technology abroad, have been used for aeroengine turbine blade high temperature anti-corrosion insulation ceramic coating, to improve the thermal shock resistance of the coating and the life. Electron beam lithography and electron beam irradiation curing resin matrix composites technology is at the research stage.
Electron beam processing technology in the future should actively expand professional field, closely tracking the international advanced technology development, in view of the demand, focus on key techniques of electron beam physical vapor deposition, the main bearing structure electron beam welding, electron beam irradiation curing technology study, key techniques of electron beam welding machine, etc.
3. The ion beam and plasma processing technology
Function of surface coating has high hardness, wear resistance, corrosion resistance function, can significantly improve the life of the parts, with wide USES in industry.
Currently in the United States and European countries most use microwave ECR plasma source to the preparation of various functional coatings. Plasma body spraying technology already in engineering application, has been widely used in aviation, aerospace, ships, etc. Products are key components in the field of wear-resistant coating, seal coating, thermal barrier coating and heat shielding layer, etc.
Plasma welding has been successfully applied to 18 mm storage tank welding of aluminum alloy. Equipped with robots and plasma welding seam tracking system in complex space welding seam has practical application. Microbeam plasma welding are widely used in precision components of welding. Plasma spraying has been applied to weapons and equipment of developed in our country, mainly used in wear-resistant coating, seal coating, high temperature protection coating and thermal barrier coating.
Vacuum plasma spraying technology and omni-directional ion implantation technology has begun to study, with abroad still has big distance. Plasma welding is used in the production, but the welding quality is not stable.
Ion beam and plasma processing technology in the future should be combined with the results have been achieved, according to demand, and ion implantation on the thermal barrier coating on the surface modification of the new technology research, at the same time, on the basis of the already obtained preliminary results, further research on plasma welding technology.
4. Electric processing technology
Widely used abroad, electrochemical machining, in addition to the blade and the integral impeller has expanded to the casing, the plate of ring parts and deep hole processing, using electrochemical machining can work out high precision metal reflective mirror. Current electrochemical machining machine tool capacity has reached 50000 amps, and has set up a CNC control and multiple parameter adaptive control. With holes on the electrical discharge machining using multi-channel and nanosecond ultra high frequency pulse power and electrode processing of special equipment at the same time, more 2 ~ 3 seconds/hole machining efficiency, surface roughness Ra0.4 microns, general high-grade electric spark forming and cutting has been able to provide micron grade machining precision, can be processed 3 microns of micro hole axis and 5 microns. Precision pulse electrolysis technology has amounted to about 10 microns. Electrolysis with edm compound machining and electrolytic grinding, edm grinding has been used in production.
According to the status quo, the development direction of special processing technology should be:
(1) continuous improvement, improve the quality of the high energy beam source, and to develop in the direction of high power, high reliability.
(2) high energy beam machining equipment to muti_function, motors and intelligent direction, makes every effort to achieve the goal of standardization, seriation and modularization. Expand the application scope, to develop in the direction of composite processing.
(3) is steadily high energy beam machining new technologies, new processes, new equipment engineering and industrialization of work.
Above to achieve development goals, must carry out the following processing technology research:
(1) laser processing technology
Micro cracks to cast layer, efficient laser processing technology research with holes on the turbine blades;
titanium alloy, aluminum alloy, super steel dissimilar material artifacts and laser welding process of large curved surface parts research, three-dimensional laser cutting process specification and surface quality of the online measuring control technology and control technology research and improve the high temperature alloy, aluminium alloy, and other important components impact fatigue resistance of laser technology research; High-power laser rapid prototyping technology research, laser cladding ceramic coating technology and coating structure and performance study.
(2) electron beam processing technology
150 kv and 15 kw high pressure gun and high voltage power supply technology research;
Electron beam physical vapor deposition technology research;
Large thickness of the cross-section of electron beam welding technology of titanium alloy research and quality evaluation;
Typical electron beam curing process of composite aircraft components research and engineering research;
Multifunctional electron beam processing technology research.
(3) the ion beam and plasma processing technology
Complex parts "conformal implantation and mixed deposition technology research, to obtain high density plasma method research; Spatial structure of welding technology parameter adaptive control and weld automatic tracking system, in the process of the plasma arc welding and deformation control technology research; Plasma spraying ceramic thermal barrier coating structure, technology and engineering research; Laminar-turbulent automatic conversion technology and axial feeding, three-dimensional spraying technology research; Laminar plasma spraying, system development and its spraying technology research.
(4) machining technology
High quality deep hole electro-hydraulic beam processing technology research;
High efficiency, high quality photographic electrochemical machining technology research group of hole;
Multi-spindle, multi-channel electrical discharge machining of holes, special-shaped hole technology research;
The large capacity (5000 a and above) precision electrochemical machining technology research;
Electrolysis - edm compound machining technology research.
Study the technical key is: improve the quality of the high energy beam; To carry out special processing of automatic control and computer modeling and simulation technology research; New materials processing characteristics research; Research of special processing equipment, etc.
特種加工概論
特種加工亦稱“非傳統(tǒng)加工”或“現(xiàn)代加工方法”，泛指用電能、熱能、光能、電化學(xué)能、化學(xué)能、聲能及特殊機(jī)械能等能量達(dá)到去除或增加材料的加工方法。本文所述的特種加工技術(shù)主要是指激光加工技術(shù)、電子束加工技術(shù)、離子束及等離子加工技術(shù)和電加工技術(shù)等。
隨著新型武器裝備的發(fā)展，國(guó)內(nèi)外對(duì)特種加工技術(shù)的需求日益迫切。不論飛機(jī)、導(dǎo)彈，還是其它作戰(zhàn)平臺(tái)都要求降低結(jié)構(gòu)重量，提高飛行速度，增大航程，降低燃油消耗，達(dá)到戰(zhàn)技性能高、結(jié)構(gòu)壽命長(zhǎng)、經(jīng)濟(jì)可承受性好。為此，上述武器系統(tǒng)和作戰(zhàn)平臺(tái)都要求采用整體結(jié)構(gòu)、輕量化結(jié)構(gòu)、先進(jìn)冷卻結(jié)構(gòu)等新型結(jié)構(gòu)，以及鈦合金、復(fù)合材料、粉末材料、金屬間化合物等新材料。
為此，需要采用特種加工技術(shù)，以解決武器裝備制造中用常規(guī)加工方法無(wú)法實(shí)現(xiàn)的加工難題，所以特種加工技術(shù)的主要應(yīng)用領(lǐng)域是：
難加工材料，如鈦合金、耐熱不銹鋼、高強(qiáng)鋼、復(fù)合材料、工程陶瓷、金剛石、紅寶石、硬化玻璃等高硬度、高韌性、高強(qiáng)度、高熔點(diǎn)材料。
難加工零件，如復(fù)雜零件三維型腔、型孔、群孔和窄縫等的加工。
剛度零件，如薄壁零件、彈性元件等零件的加工。
高能量密度束流實(shí)現(xiàn)焊接、切割、制孔、噴涂、表面改性、刻蝕和精細(xì)加
1. 激光加工技術(shù)
國(guó)外激光加工設(shè)備和工藝發(fā)展迅速，現(xiàn)已擁有100kW的大功率CO2激光器、kW級(jí)高光束質(zhì)量的Nd:YAG固體激光器，有的可配上光導(dǎo)纖維進(jìn)行多工位、遠(yuǎn)距離工作。激光加工設(shè)備功率大、自動(dòng)化程度高，已普遍采用CNC控制、多坐標(biāo)聯(lián)動(dòng)，并裝有激光功率監(jiān)控、自動(dòng)聚焦、工業(yè)電視顯示等輔助系統(tǒng)。
激光制孔的最小孔徑已達(dá)0.002mm，已成功地應(yīng)用自動(dòng)化六坐標(biāo)激光制孔專用設(shè)備加工航空發(fā)動(dòng)機(jī)渦輪葉片、燃燒室氣膜孔，達(dá)到無(wú)再鑄層、無(wú)微裂紋的效果。
激光切割適用于由耐熱合金、鈦合金、復(fù)合材料制成的零件。目前薄材切割速度可達(dá)15m/min，切縫窄，一般在0.1～1mm之間，熱影響區(qū)只有切縫寬的10%～20%，最大切割厚度可達(dá)45mm，已廣泛應(yīng)用于飛機(jī)三維蒙皮、框架、艦船船身板架、直升機(jī)旋翼、發(fā)動(dòng)機(jī)燃燒室等。
激光焊接薄板已相當(dāng)普遍，大部分用于汽車工業(yè)、宇航和儀表工業(yè)。激光精微焊接技術(shù)已成為航空電子設(shè)備、高精密機(jī)械設(shè)備中微型件封裝結(jié)點(diǎn)的微型連接的重要手段。
激光表面強(qiáng)化、表面重熔、合金化、非晶化處理技術(shù)應(yīng)用越來(lái)越廣，激光微細(xì)加工在電子、生物、醫(yī)療工程方面的應(yīng)用已成為無(wú)可替代的特種加工技術(shù)。
激光快速成型技術(shù)已從研究開(kāi)發(fā)階段發(fā)展到實(shí)際應(yīng)用階段，已顯示出廣闊的應(yīng)用前景。
國(guó)內(nèi)70年代初已開(kāi)始進(jìn)行激光加工的應(yīng)用研究，但發(fā)展速度緩慢。在激光制孔、激光熱處理、焊接等方面雖有一定的應(yīng)用，但質(zhì)量不穩(wěn)定。目前已研制出具有光纖傳輸?shù)墓腆w激光加工系統(tǒng)，并實(shí)現(xiàn)光纖耦合三光束的同步焊接和石英表芯的激光焊接。完成了激光燒結(jié)快速成型原理樣機(jī)研制，并采用環(huán)氧聚脂和樹(shù)脂砂燒結(jié)粉末材料，快速成型出典型零件，如葉輪、齒輪。
激光加工技術(shù)今后幾年應(yīng)結(jié)合已取得的預(yù)研成果，針對(duì)需求，重點(diǎn)開(kāi)展無(wú)缺陷氣膜小孔的激光加工及實(shí)時(shí)檢控技術(shù)、高強(qiáng)鋁(含鋁鋰、鋁鎂)合金的激光焊接技術(shù)、金屬零件的激光粉末燒結(jié)快速成型技術(shù)、激光精密加工及重要構(gòu)件的激光沖擊強(qiáng)化等項(xiàng)目的研究。實(shí)現(xiàn)高溫渦輪發(fā)動(dòng)機(jī)氣膜孔無(wú)缺陷加工，可使葉片使用壽命達(dá)2000小時(shí)以上；以焊代替數(shù)控加工飛機(jī)次承力構(gòu)件，以及帶筋壁板的以焊代鉚；實(shí)現(xiàn)重要零部件的表面強(qiáng)化，提高安全性、可靠性等，從而使先進(jìn)的激光制造技術(shù)在軍事工業(yè)中發(fā)揮更大的作用。
2.電子束加工技術(shù)
電子束加工技術(shù)在國(guó)際上日趨成熟，應(yīng)用范圍廣。國(guó)外定型生產(chǎn)的40kV～300kV的電子槍(以60kV、150kV為主)，已普遍采用CNC控制，多坐標(biāo)聯(lián)動(dòng)，自動(dòng)化程度高。電子束焊接已成功地應(yīng)用在特種材料、異種材料、空間復(fù)雜曲線、變截面焊接等方面。目前正在研究焊縫自動(dòng)跟蹤、填絲焊接、非真空焊接等，最大焊接熔深可達(dá)300mm，焊縫深寬比20：1。電子束焊已用于運(yùn)載火箭、航天飛機(jī)等主承力構(gòu)件大型結(jié)構(gòu)的組合焊接，以及飛機(jī)梁、框、起落架部件、發(fā)動(dòng)機(jī)整體轉(zhuǎn)子、機(jī)匣、功率軸等重要結(jié)構(gòu)件和核動(dòng)力裝置壓力容器的制造。如：F-22戰(zhàn)斗機(jī)采用先進(jìn)的電子束焊接，減輕了飛機(jī)重量，提高了整機(jī)的性能；“蘇-27”及其它系列飛機(jī)中的大量承力構(gòu)件，如起落架、承力隔框等，均采用了高壓電子束焊接技術(shù)。
國(guó)內(nèi)多種型號(hào)的飛機(jī)及發(fā)動(dòng)機(jī)和多種型號(hào)的導(dǎo)彈殼體、油箱、尾噴管等結(jié)構(gòu)件均已采用了電子束焊接。因此，電子束焊接技術(shù)的應(yīng)用越來(lái)越廣泛，對(duì)電子束焊接設(shè)備的需求量也越來(lái)越大。
國(guó)外的電子束焊機(jī)，以德國(guó)、美國(guó)、法國(guó)、烏克蘭等為代表，已達(dá)到了工程化生產(chǎn)。其特點(diǎn)是采用變頻電源，設(shè)備的體積、噪聲、高壓性能等方面都有很大提高；在控制系統(tǒng)方面，運(yùn)用了先進(jìn)的計(jì)算機(jī)技術(shù)，采用了先進(jìn)的CNC及PLC技術(shù)，使設(shè)備的控制更可靠，操作更簡(jiǎn)便、直觀。
國(guó)外真空電子束物理氣相沉積技術(shù)，已用于航空發(fā)動(dòng)機(jī)渦輪葉片高溫防腐隔熱陶瓷涂層，提高了涂層的抗熱沖擊。
性能及壽命。電子束刻蝕、電子束輻照固化樹(shù)脂基復(fù)合材料技術(shù)正處于研究階段。電子束加工技術(shù)今后應(yīng)積極拓展專業(yè)領(lǐng)域，緊密跟蹤國(guó)際先進(jìn)技術(shù)的發(fā)展，針對(duì)需求，重點(diǎn)開(kāi)展電子束物理氣相沉積關(guān)鍵技術(shù)研究、主承力結(jié)構(gòu)件電子束焊接研究、電子束輻照固化技術(shù)研究、電子束焊機(jī)關(guān)鍵技術(shù)研究等。
3.離子束及等離子體加工技術(shù)
表面功能涂層具有高硬度、耐磨、抗蝕功能，可顯著提高零件的壽命，在工業(yè)上具有廣泛用途。
美國(guó)及歐洲國(guó)家目前多數(shù)用微波ECR等離子體源來(lái)制備各種功能涂層。等離子體熱噴涂技術(shù)已經(jīng)進(jìn)入工程化應(yīng)用，已廣泛應(yīng)用在航空、航天、船舶等領(lǐng)域的產(chǎn)品關(guān)鍵零部件耐磨涂層、封嚴(yán)涂層、熱障涂層和高溫防護(hù)層等方面。
等離子焊接已成功應(yīng)用于18mm鋁合金的儲(chǔ)箱焊接。配有機(jī)器人和焊縫跟蹤系統(tǒng)的等離子體焊在空間復(fù)雜焊縫的焊接也已實(shí)用化。微束等離子體焊在精密零部件的焊接中應(yīng)用廣泛。我國(guó)等離子體噴涂已應(yīng)用于武器裝備的研制，主要用于耐磨涂層、封嚴(yán)涂層、熱障涂層和高溫防護(hù)涂層等。
真空等離子體噴涂技術(shù)和全方位離子注入技術(shù)已開(kāi)始研究，與國(guó)外尚有較大差距。等離子體焊接在生產(chǎn)中雖有應(yīng)用，但焊接質(zhì)量不穩(wěn)定。
離子束及等離子體加工技術(shù)今后應(yīng)結(jié)合已取得的成果，針對(duì)需求，重點(diǎn)開(kāi)展熱障涂層及離子注入表面改性的新技術(shù)研究，同時(shí)，在已取得初步成果的基礎(chǔ)上，進(jìn)一步開(kāi)展等離子體焊接技術(shù)研究。
4. 電加工技術(shù)
國(guó)外電解加工應(yīng)用較廣，除葉片和整體葉輪外已擴(kuò)大到機(jī)匣、盤環(huán)零件和深小孔加工，用電解加工可加工出高精度金屬反射鏡面。目前電解加工機(jī)床最大容量已達(dá)到5萬(wàn)安培，并已實(shí)現(xiàn)CNC控制和多參數(shù)自適應(yīng)控制。電火花加工氣膜孔采用多通道、納秒級(jí)超高頻脈沖電源和多電極同時(shí)加工的專用設(shè)備，加工效率2～3秒/孔，表面粗糙度Ra0.4μm，通用高檔電火花成型及線切割已能提供微米級(jí)加工精度，可加工3μm的微細(xì)軸和5μm的孔。精密脈沖電解技術(shù)已達(dá)10μm左右。電解與電火花復(fù)合加工，電解磨削、電火花磨削已用于生產(chǎn)。
根據(jù)上述現(xiàn)狀，今后特種加工技術(shù)的發(fā)展方向應(yīng)是：
(1)不斷改進(jìn)、提高高能束源品質(zhì)，并向大功率、高可靠性方向發(fā)展。
(2)高能束流加工設(shè)備向多功能、精密化和智能化方向發(fā)展，力求達(dá)到標(biāo)準(zhǔn)化、系列化和模塊化的目的。擴(kuò)大應(yīng)用范圍，向復(fù)合加工方向發(fā)展。
(3)不斷推進(jìn)高能束流加工新技術(shù)、新工藝、新設(shè)備的工程化和產(chǎn)業(yè)化工作。
為實(shí)現(xiàn)以上發(fā)展目標(biāo)，必須開(kāi)展下列加工工藝的技術(shù)研究：
(1)激光加工技術(shù)
無(wú)再鑄層、無(wú)微裂紋渦輪葉片氣膜孔激光高效加工技術(shù)研究；
鋁合金、超強(qiáng)鋼、鈦合金、異種材料構(gòu)件以及大型空間曲面零件的激光焊接工藝研究，三維激光切割工藝規(guī)范及表面質(zhì)量控制技術(shù)和在線測(cè)量控制技術(shù)研究提高高溫合金、鋁合金等重要部件抗疲勞性能的激光沖擊技術(shù)研究；激光快速成型技術(shù)研究，大功率激光熔覆陶瓷涂層的工藝以及涂層組織結(jié)構(gòu)和性能的研究。
(2)電子束加工技術(shù)
150kV、15kW高壓電子槍及高壓電源的技術(shù)研究；
電子束物理氣相沉積技術(shù)的研究；
大厚度變截面鈦合金的電子束焊接技術(shù)研究及質(zhì)量評(píng)定；
典型復(fù)合材料飛機(jī)構(gòu)件的電子束固化工藝研究及其工程化研究；
多功能電子束加工技術(shù)研究。
(3)離子束和等離子體加工技術(shù)
復(fù)雜零件“保形”離子注入與混合沉積技術(shù)研究，獲得高密度等離子體方法研究；空間結(jié)構(gòu)焊接工藝參數(shù)自適應(yīng)控制及焊縫自動(dòng)跟蹤系統(tǒng)研究，以及等離子弧焊過(guò)程中變形控制技術(shù)研究；等離子噴涂陶瓷熱障涂層結(jié)構(gòu)、工藝及工程化研究；層流湍流自動(dòng)轉(zhuǎn)換技術(shù)及軸向送粉、三維噴涂技術(shù)研究；層流等離子體噴涂系統(tǒng)的研制及其噴涂技術(shù)的研究。
(4)電加工技術(shù)
高品質(zhì)深小孔電液束加工技術(shù)研究；
高效、優(yōu)質(zhì)照相電解加工群孔技術(shù)研究；
多軸、多通道電火花加工群孔、異形孔技術(shù)研究；
大容量(5000A及以上)精密電解加工技術(shù)研究；
電解—電火花復(fù)合加工技術(shù)研究。
研究上述技術(shù)的關(guān)鍵在于：提高高能束流的品質(zhì)；開(kāi)展特種加工過(guò)程的自動(dòng)控制及計(jì)算機(jī)建模、仿真技術(shù)的研究；新材料加工特性研究；特種加工設(shè)備的研究等。