国产宽体客机项目已宣布启动，围绕宽体客机研制中装配过程重大需求，结合复合材料应用比例的大幅度提高带来的制造难题，针对大厚度CFRP/钛合金叠层构件大直径孔加工过程易出现加工损伤且几何精度难以满足要求的瓶颈问题，本申请项目拟开展基于混联机器人的复合材料/钛合金大深径高精度低损伤制孔关键技术研究。采用理论分析、仿真和试验相结合的方法，考虑混联机器人高刚度特点，建立五自由度混联机器人加工过程动力学模型，构建混联机器人制孔过程误差传递模型，研究加工损伤产生机理；研究机器人刚度，切削变量，与加工精度与损伤的关系；探究加工精度与损伤和孔疲劳性能的映射规律；研究误差补偿机制和损伤抑制策略；以含孔件疲劳性能为目标，优化制孔工艺和刀具；基于此，在混联机器人平台上进行高精度低损伤螺旋铣孔工艺试验验证；形成一整套大深径叠层构件制孔工艺方法。为国产宽体客机研制过程相关制造工艺的制定提供理论依据和技术支撑。

With the project initiation of domestic wide-body aircraft and the major demands in the aircraft assembly process, the increased use of CFRP materials in aircraft structures has in turn created enormous challenges for the industry, especially due to the surface damages and geometric precision problem that arise from the large size hole-making process for CFRP/titanium alloy stack materials. In this context, the herein project aims to explore the key issue of high precision and low damage large depth/diameter hole-making process of CFRP/titanium alloy based on the hybrid robots. For this aim, a number of technical fundamentals will be investigated based on the combination of theoretical analysis, simulation and experimental methods: dynamic and error transmission model of 5 DOF hybrid robot in hole-making process, machining damage formation mechanism, relationship between robot stiffness, cutting parameters with machining accuracy and surface damage, influence of hole-making accuracy and damage on fatigue properties of joint hole, error compensation mechanism and damage suppression strategy, cutting parameters and cutting tool optimization to obtain the better fatigue performance, etc. The experimental validation for high precision and low damage helical milling with hybrid robot platform will be conducted and a complete set of hole-making methods for large depth and diameter stack structure will be established. The outcome of the project will lay down a solid theoretical and technical foundation for the domestic wide-body aircraft manufacturing process.