CN110911847A - A combined manufacturing method of a large-curvature hyperbolic high-precision reflective panel - Google Patents
A combined manufacturing method of a large-curvature hyperbolic high-precision reflective panel Download PDFInfo
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- 238000004519 manufacturing process Methods 0.000 title claims abstract description 35
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 claims abstract description 45
- 229910052782 aluminium Inorganic materials 0.000 claims abstract description 45
- 238000003801 milling Methods 0.000 claims abstract description 38
- 238000000034 method Methods 0.000 claims abstract description 29
- 230000008569 process Effects 0.000 claims abstract description 17
- 238000003698 laser cutting Methods 0.000 claims abstract description 9
- 239000000463 material Substances 0.000 claims description 36
- 238000007789 sealing Methods 0.000 claims description 13
- 229910001220 stainless steel Inorganic materials 0.000 claims description 7
- 239000010935 stainless steel Substances 0.000 claims description 7
- 238000013461 design Methods 0.000 claims description 6
- 239000000853 adhesive Substances 0.000 claims description 2
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- 238000000638 solvent extraction Methods 0.000 claims 1
- 210000000282 nail Anatomy 0.000 abstract description 60
- 210000004904 fingernail bed Anatomy 0.000 abstract description 9
- 238000005259 measurement Methods 0.000 abstract description 8
- 229920006332 epoxy adhesive Polymers 0.000 abstract description 6
- 239000010410 layer Substances 0.000 description 46
- 241000264877 Hippospongia communis Species 0.000 description 38
- 238000012545 processing Methods 0.000 description 9
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- 238000004026 adhesive bonding Methods 0.000 description 5
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- 230000005540 biological transmission Effects 0.000 description 2
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01Q—ANTENNAS, i.e. RADIO AERIALS
- H01Q15/00—Devices for reflection, refraction, diffraction or polarisation of waves radiated from an antenna, e.g. quasi-optical devices
- H01Q15/14—Reflecting surfaces; Equivalent structures
- H01Q15/141—Apparatus or processes specially adapted for manufacturing reflecting surfaces
- H01Q15/142—Apparatus or processes specially adapted for manufacturing reflecting surfaces using insulating material for supporting the reflecting surface
- H01Q15/144—Apparatus or processes specially adapted for manufacturing reflecting surfaces using insulating material for supporting the reflecting surface with a honeycomb, cellular or foamed sandwich structure
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01Q—ANTENNAS, i.e. RADIO AERIALS
- H01Q15/00—Devices for reflection, refraction, diffraction or polarisation of waves radiated from an antenna, e.g. quasi-optical devices
- H01Q15/14—Reflecting surfaces; Equivalent structures
- H01Q15/16—Reflecting surfaces; Equivalent structures curved in two dimensions, e.g. paraboloidal
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Abstract
本发明公开一种大曲率双曲度高精度反射面板的组合制造方法，该反射面板包括三层铝板、两层耐久型蜂窝芯和用于胶结的室温固化双组改性环氧胶黏剂，三层铝板分别为工作板、中接板和背板；所述制造方法包括：大曲率双曲度高精度反射面板的三维建模、三层铝板的空间几何展开及在钉床上的定位、激光切割三层铝板展开坯料、钉高的计算以及三层铝板在高精度钉床上的定位；逐层铺设三层铝板及两层蜂窝、夹层板在铣床平台上的定位、铣床的对刀及最终夹层板的铣削加工是大曲率双曲度高精度反射面板制造的主要过程。本发明方法解决了大曲率双曲度反射面板的制造难题，可实现适用于太赫兹天线测量的大曲率、高精度、大比刚度、轻量化的反射面板的制造。
The invention discloses a combined manufacturing method of a large-curvature hyperbolic high-precision reflective panel. The reflective panel comprises three layers of aluminum plates, two layers of durable honeycomb cores and a room temperature curing two-group modified epoxy adhesive for bonding. The three-layer aluminum plate is a working plate, a middle plate and a back plate respectively; the manufacturing method includes: three-dimensional modeling of a large-curvature hyperbolic high-precision reflective panel, spatial geometric expansion of the three-layer aluminum plate and positioning on the nail bed, laser Cutting the three-layer aluminum plate and unfolding the billet, calculating the nail height and positioning the three-layer aluminum plate on the high-precision nail bed; laying the three-layer aluminum plate and the two-layer honeycomb and the positioning of the sandwich plate on the milling machine platform layer by layer, the milling machine tool setting and the final sandwich The milling process of the plate is the main process for the manufacture of high-precision reflective panels with large curvature and double curvature. The method of the invention solves the manufacturing problem of the large-curvature hyperbolic reflective panel, and can realize the manufacture of a large-curvature, high-precision, large-specific stiffness, and lightweight reflective panel suitable for terahertz antenna measurement.
Description
Technical Field
The invention relates to a combined manufacturing method of a large-curvature double-curvature high-precision reflection panel, in particular to a manufacturing process method of a large-curvature double-curvature continuous surface high-precision honeycomb sandwich structure reflection panel, and belongs to the field of mechanical engineering/precision manufacturing.
Background
With the rapid development of terahertz (THz) waves in the fields of radar detection, communication transmission, terahertz remote sensing, nondestructive testing and the like, the demand for high-gain antennas for transmitting and receiving terahertz waves is more and more extensive, so that higher requirements are put forward on compact field antenna measurement technologies. In order to realize the terahertz antenna measurement technology, the operating frequency of the compact field needs to be more than 100G, namely, the profile accuracy (RMS value, root mean square error) of the reflecting surface of the compact field is required to be less than 30 μm, and the surface roughness (Ra) is required to be less than 1.2 μm. Meanwhile, the compact field reflecting surface measurement technology is developing towards large curvature, and the manufacturing difficulty is increased. Although the existing direct precise processing technology of the solid casting blank can obtain the high-quality profile precision of the reflecting panel, the cutting amount is overlarge, and the profile precision of the panel is obviously changed due to the self weight and temperature change; the vacuum negative pressure precision forming process can only effectively solve and ensure the precision problem of the panel with small curvature compact range, and the forming precision of the panel with large curvature is poor.
The invention relates to a high-precision reflecting panel which comprises three layers of aluminum plates, two layers of durable aluminum honeycomb cores and room temperature curing double-group modified epoxy adhesive, wherein the three layers of aluminum plates, the two layers of durable aluminum honeycomb cores and the room temperature curing double-group modified epoxy adhesive are paved on a flexible multipoint mould layer by layer, vacuum negative pressure is formed by sealing a vacuum bag, forming, cementing and curing of the panel and a honeycomb are realized simultaneously, the honeycomb sandwich structure reflecting panel (hereinafter referred to as a sandwich plate) with initial precision is manufactured, and the ultrahigh precision of the sandwich plate is realized by an ultraprecise milling process.
In addition, the applicant has learned in a large number of studies and experiments that the following problems mainly exist in the prior art:
1. the high-precision reflecting panel manufactured in the prior art is manufactured by directly processing the surface of a solid casting blank by using precision processing equipment, but the cutting amount is large, the processing cost is high, the period is long, the weight of the panel is large, the deformation caused by temperature and gravity has large influence on the profile precision of a sandwich plate, and the profile precision stability of the panel is difficult to guarantee.
2. The high-precision reflecting panel is manufactured by adopting a honeycomb sandwich structure, and the three layers of aluminum plates adopt a slotted stress release technology, but are only suitable for manufacturing the reflecting panel with small curvature. For the large-curvature reflecting panel, the whole structure still has large resilience, and the forming precision is poor.
3. In the vacuum negative pressure precision forming process, a vacuumizing system is utilized to apply uniform load to the sandwich plate, so that the sandwich plate is fully attached to a die. In the pressing and pasting process, when the uniformly distributed load is smaller than the corresponding critical pressure value when the aluminum plate is completely pasted with the die, part of the pressure is absorbed by the honeycomb and the aluminum plate in the transmission process, so that the working plate is not completely pasted with the die; when the equipartition load was greater than the critical pressure value, the working plate can directly appear excessive die-attaching phenomenon, or the honeycomb is conquashed, and the bullet that leads to the sandwich panel storage becomes to strain can too big, in case after the demoulding, excessive resilience appears in the sandwich panel, is difficult to maintain the profile precision of sandwich panel. Meanwhile, as the curvature of the panel increases, the relative arch height value increases, and the required die pressing pressure also increases gradually. Therefore, the accuracy of the profile of the sandwich plate is easily uncontrollable due to improper forming pressure, and a processing technical scheme is urgently needed for correcting the accuracy of the profile of the sandwich plate with curvature.
Disclosure of Invention
The invention aims to provide a combined manufacturing method of a large-curvature double-curvature high-precision reflecting panel, which realizes the technical aims of high precision, large curvature, large specific stiffness and light weight required by the terahertz compact range measuring technology.
The basic principle of the invention is as follows: modeling according to the spatial position of a single reflection panel, obtaining a blank processing diagram of the three-layer aluminum plate by utilizing an expansion algorithm of a spatial curved surface, determining the relative position of the blank processing diagram, and obtaining an expanded blank of the three-layer aluminum plate by utilizing laser cutting; based on nail height calculation software, calculating nail height data of the panel forming multi-point die according to a parting line equation of a single panel, and adjusting a high-precision discrete nail die according to the nail height data; covering a stainless steel base plate coated with lubricating oil on the nail die, spreading glue on the contact surfaces of the three layers of aluminum plates and the two layers of honeycombs one by one on the base plate, and positioning; sealing with a sealing cover and then forming vacuum negative pressure through a vacuum pump; after the pressure maintaining for 48 hours, the curing is finished, and the reflecting panel is taken out from the nail bed and subjected to edge sealing process; and fixing the reflecting panel on a milling machine platform by adopting a flexible clamping system based on a vacuum chuck, and setting proper technological parameters to mill the working plate. The technical goals of high precision, large curvature, large specific stiffness and light weight required by the terahertz compact field measurement technology are achieved.
The invention relates to a combined manufacturing method of a large-curvature double-curvature high-precision reflecting panel, wherein the high-precision reflecting panel is of an interlayer structure and specifically comprises three layers of aluminum plates, two layers of honeycomb cores and room-temperature curing double-group modified epoxy adhesive for connecting the aluminum plates and the honeycomb cores; the three-layer aluminum plate is a working plate, the middle connecting plate and the back plate, the two honeycomb cores are a first honeycomb core and a second honeycomb core, and the room-temperature-curing double-group modified epoxy adhesive is used for gluing the aluminum plate and the honeycomb cores.
The invention discloses a combined manufacturing method of a large-curvature double-curvature high-precision reflecting panel, which comprises the following steps of:
1. drawing a theoretical curve of the working plate according to a curve equation under a YZ plane of a default coordinate system of numerical control programming software (such as Catia), and taking the theoretical curve as a bus to rotate around a Z axis for a circle to form a theoretical curved surface of the working plate;
2. according to the blocking scheme, the theoretical curved surface of the working plate is divided to form a single theoretical curved surface of the working plate;
3. establishing a tangent plane of the theoretical curved surface of the single working plate by taking the highest point of the arch height of the theoretical curved surface of the single working plate as a base point, then establishing a design coordinate system of the theoretical curved surface of the working plate by taking the highest point of the arch height of the theoretical curved surface of the single working plate as an origin of coordinates and the normal direction of the tangent plane as a Z direction and the normal direction of a YZ plane of a default coordinate system of numerical control programming software (such as Catia) as an X direction, and expanding the theoretical curved surface of the single working plate on an XOY plane of the design coordinate system to form a single working plate expanding material;
4. passing through two diagonal lines of the theoretical curved surface of the single working plate, wherein the intersection point of the diagonal lines is the original point of a manufacturing coordinate system and is also the center of the discrete nail mold; determining the relative position of the highest point of arch height of the single working plate spread material and the center of the discrete nail die, pre-positioning the single working plate spread material on the discrete nail die, and determining the position of a positioning hole of the single working plate spread material according to the layout of the discrete nail die.
5. Taking the single working plate unfolding material as a reference, keeping the highest point of arch height and the position of the positioning hole unchanged, inwards deviating by 7-12 mm along the normal direction of the edge, and trimming redundant sidelines to form the single middle joint plate unfolding material;
6. taking the single working plate unfolding material as a reference, keeping the highest point of arch height and the position of the positioning hole unchanged, inwards deviating by 5-9 mm along the normal direction of the edge, and trimming redundant sidelines to form a single back plate unfolding material;
7. laser cutting the unfolded material of the three layers of aluminum plates;
8. according to a parting line equation of the high-precision reflecting panel, nail height data of the multi-point die are calculated based on nail height calculation software, and high-precision discrete nail dies are adjusted according to the nail height data to form an envelope surface of a theoretical curved surface of a single working plate;
9. positioning the single working plate unfolding material, the single middle plate unfolding material and the single back plate unfolding material on the discrete nail die by using the positioning holes respectively;
10. covering a stainless steel base plate on the discrete nail mold with the well-adjusted enveloping surface and positioning, sequentially laying a working plate, a first honeycomb core, a middle joint plate, a second honeycomb core and a back plate on the base plate and positioning, coating epoxy resin adhesives on the back surface of the working plate (the connecting surface of the working plate and the first honeycomb core), two surfaces of the middle joint plate and the back surface of the back plate (the connecting surface of the back plate and the second honeycomb core), laying layer by layer, sealing and vacuumizing; after the pressure maintaining for 48 hours, the curing is finished, and the reflecting panel is taken out from the discrete nail mold and subjected to edge sealing process;
11. fixing the reflection panel after edge sealing on a milling machine platform by adopting a flexible clamping system based on a vacuum chuck;
12. after the digital-analog position alignment and the programming origin point determination are realized, the process of moving the sandwich plate from the manufacturing coordinate system to the milling machine coordinate system is completed.
13. And setting appropriate process parameters, and adopting a processing method of 2-3 times of rough milling and 1 time of finish milling for the sandwich structure panel to finally obtain the high-precision honeycomb sandwich structure reflecting panel with large curvature.
The curvature radius of the large-curvature high-precision honeycomb sandwich structure reflecting panel is required to be less than 10 m, the profile precision is required to be less than 30 microns, the thickness of the working plate is 1.5 mm, the thickness of the middle joint plate is 1 mm, the thickness of the back plate is 1.5 mm, and the thickness of the honeycomb core is 50 mm.
The invention relates to a combined manufacturing method of a large-curvature double-curvature high-precision reflecting panel, which has the advantages and effects that: the invention adopts the processing technology of combining the high-precision panel precision forming process and the precision milling process based on lattice nail mold, vacuum negative pressure, honeycomb interlayer and stress release to manufacture the large-curvature double-curvature high-precision reflecting panel, and has the advantages that the vacuum negative pressure is utilized to glue three layers of aluminum plates and two layers of honeycombs on the envelope surface formed by the high-precision flexible discrete nail mold, a double-interlayer structure with higher specific rigidity and stronger temperature deformation resistance is formed by curing, the curvature requirement of the panel is met, and the initial profile precision is obtained; then, the sandwich structure panel is processed for 3-4 times by an ultra-precise milling process, the cutting amount is far smaller than that of the solid structure, the problem of integral resilience of the sandwich structure is avoided, and the profile precision of the panel is optimized; finally, the technical goals of high precision, large curvature, large specific stiffness and light weight required by terahertz measurement are achieved.
Drawings
FIG. 1 is a three-dimensional model of a work plate in the method of the present invention.
FIG. 2 shows the spatial geometrical development and positioning of three aluminum sheets on a discrete nail mold in the method of the invention.
FIG. 3 shows a vacuum chuck-based flexible clamping system for the method of the present invention.
FIG. 4 shows the tool setting of the milling machine in the method of the present invention.
FIG. 5 is a schematic diagram of the formation of a high-precision reflective panel with large curvature and double curvature according to the method of the present invention.
FIG. 6 is a schematic diagram of the ultra-precision milling process of the large-curvature double-curvature high-precision reflective panel in the method of the present invention.
FIG. 7 is a flowchart of nail height calculation software in an embodiment of the present invention.
FIG. 8 is a block diagram of a method of the present invention.
The reference numbers and symbols in the figures are as follows:
1. a working plate; 2. a middle connection plate; 3. a back plate; 4. a base plate; 5. a first honeycomb core; 6. a second honeycomb core; 7. dispersing the nail mold; 8. sealing the bag; 9. a vacuum pumping system; 10. milling cutters; 11. a sandwich structured high precision reflective panel; 12. a flexible clamping system; 13. working plate theoretical profile; 14. marking the hole; 15. unfolding the material by using a single working plate; 16. unfolding the single middle joint plate; 17. a single back plate unfolding material; 18. the highest point of the arch height of the three layers of aluminum plates is at the relative position on the nail bed; 19. the outer edge contour line of the base plate; 20. positioning round holes of the three layers of aluminum plates; 21. positioning oblong holes of the three layers of aluminum plates; 22. positioning pins; 23. a vacuum chuck; 24. a transition piece; 25. a telescopic nail; 26. nailing strips; 27. a base; 28. calibrating the block; 29. positioning a lug; 30. manufacturing a coordinate system; 31. a milling machine coordinate system;
Detailed Description
The invention relates to a combined manufacturing method of a large-curvature double-curvature high-precision reflecting panel, wherein the high-precision reflecting panel is of an interlayer structure and comprises three layers of aluminum plates, two layers of durable honeycomb cores and room-temperature curing double-set modified epoxy adhesive for cementing; the three layers of aluminum plates are respectively a working plate 1, a middle connecting plate 2 and a back plate 3, and the two layers of honeycomb cores are a first honeycomb core 5 and a second honeycomb core 6; the forming method comprises the steps of determining the three-layer aluminum plate unfolded blank of the high-precision panel honeycomb sandwich structure, carrying out laser cutting on the three-layer aluminum plate unfolded blank, calculating the nail height of the discrete nail die, positioning the three-layer aluminum plate on the high-precision discrete nail die 7, positioning the sandwich plate on a milling machine platform, carrying out tool setting on the milling machine and carrying out ultra-precision milling on the whole sandwich structure. The laser cutting of the three-layer aluminum plate unfolding blank is an element directly influencing the edge contour precision of the sandwich plate, the calculation of nail height is a basis for forming a discrete envelope surface, the accurate positioning of the three-layer hard aluminum plate on a high-precision discrete nail die is a premise for obtaining the large curvature and the profile precision of the panel, and the ultra-precision milling of the whole sandwich structure is a key for realizing the high precision of the large-curvature double-curvature reflecting panel.
The invention relates to a combined manufacturing method of a large-curvature double-curvature high-precision reflecting panel, which is mainly realized by performing three-dimensional modeling according to the curve equation of a single reflecting panel, the characteristics of positioning holes and the like, obtaining a processing blank diagram of three layers of aluminum plates through space curved surface unfolding, and obtaining an aluminum plate unfolding blank with accurate edge profile and positioning holes through laser cutting. Calculating nail height based on self-developed nail height calculation software, adjusting a high-precision discrete nail mold, laying a stainless steel base plate on the discrete nail mold, sequentially laying three layers of aluminum plates and two layers of honeycombs on the stainless steel base plate, gluing after accurate positioning, covering a sealing bag 8, curing under the vacuumizing and pressure maintaining of a vacuumizing system 9 for 48 hours to form a honeycomb sandwich structure panel with large curvature and initial profile precision, and performing edge sealing after demolding. The reflection panel after edge sealing is fixed by a flexible clamping system 12 of a vacuum chuck, after the milling cutter 10 is used for cutting the tool, the clamp plate is subjected to an ultraprecise milling process of 2-3 times of rough milling and 1 time of finish milling by setting appropriate process parameters, and finally the manufacture of the reflection panel 11 with large curvature, double curvature and high precision is realized. The overall manufacturing flow diagram is shown in fig. 8. The following is a detailed description.
Step one, establishing a three-dimensional model of the working plate according to a curve equation
Under a YZ plane of a default coordinate system of numerical control programming software (such as Catia), drawing a theoretical curve of the reflecting surface working plate according to a curve equation, and taking the theoretical curve as a bus to rotate around a Z axis for one circle to form a theoretical curved surface of the working plate; according to the blocking scheme, the theoretical curved surface of the working plate is divided to form a single theoretical curved surface of the working plate, and a measurement mark hole 14 required by measurement is established on the single theoretical curved surface of the working plate, so that a single theoretical curved surface 13 of the working plate with the measurement mark hole 14 is obtained, as shown in fig. 1.
Step (two) three-layer aluminum plate space geometric expansion and positioning on nail bed
Establishing a tangent plane of the theoretical curved surface of the single working plate by taking the highest arch height point of the theoretical curved surface 13 of the single working plate as a base point, establishing a design coordinate system of the theoretical curved surface of the working plate by taking the highest arch height point of the theoretical curved surface of the single working plate as a coordinate origin, taking the normal direction of the tangent plane as a Z direction and taking the normal direction of the YZ plane of a Catia default coordinate system as an X direction, and expanding the theoretical curved surface of the single working plate on an XOY plane of the design coordinate system to obtain an expanded material 15 of the single working plate; establishing a plane and two diagonal lines through four corner points of a theoretical curved surface of the single working plate, wherein the plane is a manufacturing coordinate system plane and is also a reference plane of the discrete nail mold; the intersection point of the two diagonal lines is the origin of a manufacturing coordinate system and is also the center of the discrete nail mold; and (3) taking an XOY plane of a coordinate system designed by the single working plate as a sketch drawing plane, and measuring a coordinate value of an original point of a manufacturing coordinate system, thereby determining the relative position 18 of the arch height highest point of the single working plate on the discrete nail mold and pre-positioning the spread material of the single working plate on the discrete nail mold 7. The method comprises the steps of arranging ball stud columns with the diameter of 12mm in a 50mm mode, determining positioning holes at stud column positions as close as possible to the edge of a working plate, wherein one end of each positioning hole is a positioning round hole 20 of three layers of aluminum plates, the other end of each positioning long round hole 21 of the three layers of aluminum plates, and the round holes and the long round holes are required to be arranged on the same row or column of top studs. Taking the single working plate unfolding material as a reference, keeping the highest point of arch height and the positioning hole unchanged, inwards deviating by 7-12 mm along the normal direction of the edge, and trimming the redundant edge lines at the edge intersection to form a complete closed wire frame, namely a single middle joint plate unfolding material 16; and taking the single working plate unfolding material as a reference, keeping the highest point of the arch height and the position of the positioning hole unchanged, inwards deviating by 5-9 mm along the normal direction of the edge, and trimming the redundant edge line at the edge intersection to form a complete closed wire frame, namely the single back plate unfolding material 17.
Step (III) laser cutting unfolding material of three layers of aluminum plates
And laser cutting is adopted to obtain a working plate unfolding material 15 with positioning holes, a middle connecting plate unfolding material 16 and a back plate unfolding material 17. When the unfolded material is cut, the positioning hole is cut firstly, and then the outer contour of the aluminum plate is cut.
Step (four), determining the size of the nail bed and calculating the nail height
The discrete pin die 7 is formed by arranging ball stud columns with the diameter of 12mm in an array of 50mm by taking the center of the discrete pin die as a base point. The outer contour of the discrete nail die is 100-200mm larger than the unfolded outer edge of the working plate, so that 2-3 rows of nail columns are arranged on the outer edge of the working plate after the working plate is positioned on the discrete nail die to ensure the forming precision of the edge of the working plate. In nail height calculation software, according to a dividing line equation after splicing of a theoretical curved surface of a working plate, dividing line coordinates (X0, X1, Y0 and Y1) of the theoretical curved surface of the working plate are set, a nail bed type and a nail head radius are selected according to actually used discrete nail dies, and a central nail column position is selected and then imported into a nail bed layout data file. After the relevant information of the discrete nail dies is confirmed, whether the theoretical curved surface of the working plate rotates 90 degrees or not is judged so as to meet the layout of the discrete nail dies. And determining a calculation elevation according to the theoretical curved surface arch height of the working plate and the actual discrete nail mold information, inputting a curved surface forming springback coefficient, and calculating nail height data of the panel to be formed. Nail height calculation flow chart details see fig. 7, and specific nail height data are shown in table 1 below, X, Y, which is the coordinate value of the nail column in the manufacturing plane, and Z is the distance from the highest point of the nail column to the plane of the panel manufacturing coordinate system.
TABLE 1
Step (V) positioning of three-layer aluminum plate on high-precision nail bed
The dowel pin 22 replaces the dowel post where the dowel hole is located. When the panel is formed, the positioning holes of the three layers of aluminum plates are aligned with the positioning pins to obtain a positioning layout of the three layers of aluminum plates on the discrete nail dies as shown in fig. 2.
Step (six) laying interlayer structure layer by layer
The layer-by-layer laying of the sandwich structure is the main process of forming the large-curvature double-curvature high-precision reflecting panel:
(1) selecting a stainless steel backing plate 4 with the outer edge profile 19 larger than the outer edge of the discrete nail mould, placing the stainless steel backing plate on the discrete nail mould obtained in the step (four) and positioning;
(2) placing the front surface of the working plate 1 on a base plate 4 coated with lubricating oil, and positioning by using positioning pins and positioning holes;
(3) gluing the back of the working plate 1, and laying the first honeycomb core 5 on the glue layer;
(4) positioning the front surface of the middle joint plate 2 on the first honeycomb core 5 after gluing;
(5) gluing the back of the middle joint plate 2, and placing a second honeycomb core 6;
(6) and (3) placing the back plate 3 coated with the glue on the second honeycomb core 6 in a downward mode, and positioning, so that the layer-by-layer laying process of the sandwich structure is completed.
(7) Finally, the reflecting panel is sealed by a vacuum bag 8, vacuum negative pressure is formed by a vacuum pump, and the pressure is kept at about 0.032MPa for 48 hours to form the reflecting panel with large curvature, double curvature and high precision, which is shown in figure 5. And demolding the reflecting panel and sealing edges.
Positioning the sandwich plate on the milling machine platform
And a flexible clamping system 12 (shown in figure 3) is adopted to perform ultra-precise milling positioning on the clamping plate. A base 27 of the clamping system is formed by a plurality of nail strips 26, horizontal calibration is carried out by a calibration block 28, telescopic nails 25 are installed on nail holes of the nail strips 26, envelope surfaces matched with the nail strips are formed according to digital-analog adjustment of a panel, and meanwhile, the telescopic nails are connected with a vacuum chuck 23 through a transition connecting piece 24; meanwhile, the vacuum sucker 23 is communicated with a vacuum pump through a connecting pipe, and the vacuum pump is used for sucking, so that the adsorption and positioning of the panel are realized. At the same time, the precise positioning of the panel is achieved with two process tabs 29.
Step (eight) of carrying out ultra-precise milling tool setting
On a milling machine platform, firstly, a probe is used for obtaining position coordinates of four measuring mark holes 14 of a panel, then, a digital model is moved to a position under a milling machine coordinate system 31 from a manufacturing coordinate system 30 by utilizing a coordinate change function of CATIA, and finally, the four measuring holes are mutually restricted and gradually approximated, so that the workpiece and the model are accurately corresponding, and the digital model position alignment process is completed. After the digifax is corresponding to the position of the workpiece, the measuring mark hole 14 at the lower left corner of the panel is taken as a programming origin, coordinates of other points on the panel are changed, the position of the programming origin under a machine tool coordinate system is determined, and the milling and tool setting of the sandwich plate are completed, as shown in figure 4.
Step (nine) milling honeycomb sandwich structure high-precision panel
Selecting a larger milling depth and a larger path distance, and carrying out rough milling on the interlayer plate for 2-3 times to obtain a profile which is as consistent as possible with the theoretical profile; then, fine milling is carried out on the interlayer plate by selecting smaller milling depth, smaller path distance and larger feeding speed; finally, the high-precision reflective panel 11 with a large curvature and a double curvature is manufactured, as shown in fig. 6.
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