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Technological Invention Award | from the source to solve the composite components of high quality processing "card neck" problem
time2018/01/09
"The use of carbon fiber reinforced epoxy resin composites, the box fastening holes of a large airliner can be decreased from more than 30 thousand to more than 1 months, weight loss of up to 15%." Jia Zhenyuan, a distinguished professor of Yangtze River scholar at Dalian University of Technology, said that using lightweight and high-strength carbon fiber composites to reduce weight and increase efficiency is significant for high-end equipment in aviation, aerospace and transportation.
However, carbon fiber composites are typical hard to be machined materials. It is very easy to produce uncontrollable damage during processing, which leads to the difficulty of ensuring and endangering the safety of the carbon fiber composites.
Jia Zhenyuan from the Dalian University of Technology led the completion of the high performance carbon fiber composite material with high quality and high efficiency processing technology and equipment, from the source address of high performance composite component and low damage digital processing "card neck" problem, a prize awarded the 2017 annual National Award for technological invention.
"The difficulty at that time was to figure out how the problem was generated, because the factors that affect the carbon fiber composite removal process are complex, and the processing damage is random and uncontrollable. Project third, Wang Fuji, Professor of Dalian University of Technology and adult said that following the traditional cutting theory of homogeneous materials such as metals, when processing carbon fiber reinforced plastics, the damage is serious and the quality is poor, so it is difficult to meet the high performance requirements of composite components.
As a team leader, Jia Zhenyuan decided to set the tone, "must break the shackles of the traditional system of metal cutting theory of homogeneous material, to establish a new theoretical system of carbon fiber composite material processing."
To establish a theoretical system, easier said than done? After hundreds of experiments, the team unveiled the mechanism of carbon fiber composite removal and the formation mechanism of processing damage. When the force is small and concentrated, the fiber is easy to cut and the damage is small. Popularly speaking, compared with the cutting depth of 10 micron and 30 micron, the small cutting depth of the former can reduce the cracking of the fiber interface, and when the tool radius is less than the fiber radius, the fiber is easier to be cut instead of folded.
"Scientific research must serve the major needs of the state. Universities should solve the problems of enterprises and industries' necking" and form an innovative system of basic research, applied basic research, technology development and product development. Jia Zhenyuan said that over the past decade, after finding out the mechanism, the team has established a new theoretical system suitable for the processing of carbon fiber composite materials. Through the adjustment of development tools and design processes, the low damage processing of carbon fiber composites has been realized.
When the Jia Zhenyuan team got the results in the basic theory research, then he turned back to carry out the practical research. After drilling and milling cutters have invented three kinds of 9 series, life is not only higher than the import tool 2-7 times, the price is only 1/6-1/4; developed 13 sets of CNC machining equipment, to fill the gaps, to become the only equipment of China's aerospace multiple key model composite key component machining.
Since 2010, the project of the new technology and equipment and tools developed to start the application, composite material processing from the original damage reduced to 0.1 centimeters, millimeters mm, cannot be realized from the manual processing or processing to the digital processing of low damage across processing technology into the international advanced level.