Technological Equipment Development Made of Material with Shape Memory Alloy for Machining Non-Rigid Parts of Aircraft

Mechanical Engineering and Machine Science


Аuthors

Nazarov D. V.1*, Nosov N. V.2**, Goryainov D. S.2***

1. Samara Federal Research Center of the Russian Academy of Sciences, Samara, Russian Federation
2. Samara State Technical University, SSTU, 244, Molodogvardeyskaya str., Samara, 443100, Russia

*e-mail: dennynaz@yandex.ru
**e-mail: nosov.nv@samgtu.ru
***e-mail: tmsi@samgtu.ru

Abstract

The article tackles the issue of the technological equipment designing for basing non-rigid workpieces such as bodies of rotation at the stage of finishing machining operations. The machining attachment (mandrel) contains a base element (sleeve), and it is intended for securing a flexible wheel, which is the main element of the wave gear transmission of the spacecraft electromechanical antenna drive. The article describes the technique for designing and indicators computing of the technological rigging for basing such type of the parts. A mandrel prototype was developed and the process of work-out was performed under real production conditions. 
The article consists of three main parts, namely the introduction, the main part and conclusions. 
The introduction considers the causes of the geometric shape deviations of non-rigid cylindrical parts in the form of the out-of-roundness and tapering associated with of the workpiece deformations occurring while workholding and machining. The authors analyzed various basing schemes options, emerging deformations and their significant impact on the overall processing error. Thus, it is urgent to control the clamping force, ensuring reliable fastening on the one hand, and avoiding unnecessary deformations of the non-rigid workpiece on the other hand. 
In the main part, the authors proposed to employ a sleeve made of the TN-1 shape memory alloy as a power element of the rig. Simulation of the interaction process between the TN-1 alloy made sleeve and a thin-walled cylindrical billet is presented as well. The article describes the simulation object, i.e. a thin-walled cylindrical workpiece and a tubular power element made of the TN-1 alloy. The model allows displacement computing of the basing outer cylindrical surface of the element made of a shape-memory material by reference to the amount of deformation induced from the side of the orifice in the radial direction. The design process algorithm for a mandrel with the TN-1 alloy made working part for basing a thin-walled precision cylindrical billet is presented in the form of a block diagram. An experimental study of the basing process of the precision thin-walled billet with an inner orifice of the 85.98 mm diameter with the of 20 microns tolerance made of the 03Cr11Ni8Mo2V material on a mandrel with a base element made of the TN-1 alloy was performed. The article presents a step-by-step description of the thin-walled workpiece installing process on the mandrel with a base element made of the TN-1 alloy by heating and subsequent cooling by dint of the tolerance fields diagram of the outer diameter of the mandrel working part and the orifice diameter of the workpiece. The process of the thin-walled workpiece removing from the mandrel is being performed in the same order. The value of the guaranteed tightness at the maximum diameter of the workpiece orifice is 0.014 mm, which corresponds to the computed pressure in the joint of 0.42 MParequired for guaranteed fastening.
It is noted in the conclusions that application of the developed design of the technological rigging allows creating fixing forces of the required value, ensuring the working stroke stability with its multiple use. Thus, geometric errors in the form of the circularity deviation are being minimized, which enhances the operational indices of the precision parts.

Keywords:

wave gear, shape memory alloy, thin-walled precision workpieces basing

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