有源相控阵雷达T/R组件Al-50wt%Si合金微槽超声铣削表面缺陷主动调控关键技术

加工合格率低和制造成本高是制约相控阵雷达T/R组件高品质制造的两大难题。建立加工表面缺陷抑制方法，获得控制刀具磨损策略，是解决上述难题的关键。针对以上两个难题，本项目面向有源相控阵雷达T/R组件精密制造工程需求，以相控阵雷达T/R组件Al-50wt%Si合金微槽超声铣削为研究对象，围绕切削材料去除机制、超声铣削表面缺陷形成机理和刀具刃口微观作用机制等关键科学问题，以及超声铣削表面缺陷预测方法、刀具磨损控制方法及表面缺陷主动调控模型等关键技术难题，开展理论建模、数值模拟和实验研究。重点研究基于多颗粒协同尺寸效应的Al-50wt%Si合金切削材料去除机制，构建基于比切削能调控的两相多因素耦合超声铣削表面缺陷预测模型，建立基于刀-屑内外摩擦转变机制的Al-50wt%Si合金超声铣削刀具磨损模型，构建基于单因素影响和多因素协同调控的微槽超声铣削缺陷主动控制工艺模型，实现T/R组件微槽的高品质制造。

Low qualification rate and high manufacturing cost are two major problems restricting the high-quality manufacturing of phased array radar T/R module. The key to solve the above problems is to establish the method to restrain the surface defects and to obtain the strategy to control the tool wear. In view of the above two problems, this project is aimed at the precise manufacturing engineering requirements of the active phased array radar T/R module. Taking the ultrasonic milling of Al-50wt% Si alloy micro groove as the research object, it focuses on the key scientific issues such as the removal mechanism of cutting materials, the formation mechanism of surface defects in ultrasonic milling and the micro action mechanism of cutting edge. The key technical problems such as the prediction method of surface defects in ultrasonic milling, the control method of tool wear and the active control model of surface defects are studied by theoretical modeling, numerical simulation and experiments. The removal mechanism of Al-50wt% Si alloy cutting materials based on multi particle collaborative size effect is studied. The prediction model of surface defects in two-phase and multi factor coupling ultrasonic milling based on specific cutting energy regulation is constructed. The wear model of Al-50wt% Si alloy ultrasonic milling tool based on the internal and external friction transformation mechanism of tool-chip is established. The micro groove ultrasonic milling based on single factor and multi factor coordinated regulation is constructed. And the process model of active defect control can realize the high quality manufacturing of T/R module micro groove.