改性复合材料表面铣削过程中球头铣刀磨损预测

doi:10.3901/JME.2025.13.231

机械工程学报 ›› 2025, Vol. 61 ›› Issue (13): 231-245.doi: 10.3901/JME.2025.13.231

• 摩擦学 • 上一篇

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改性复合材料表面铣削过程中球头铣刀磨损预测

张博宇^1,2, 孙凯^1,2, 穆晗^3,4, 郭贺阳^1,2, 孔令满^1,2, 蹇锡高^1,2

1. 大连理工大学化工学院大连 116024;
2. 大连理工大学精细化工国家重点实验室大连 116024;
3. 大连理工大学机械工程学院大连 116024;
4. 航天材料及工艺研究所北京 100076

收稿日期:2024-07-14 修回日期:2025-01-09 发布日期:2025-08-09
作者简介:张博宇(通信作者)，男，1992年出生，博士，副研究员，博士研究生导师。主要研究方向为热塑性复合材料大型构件连续热压成型技术与装备。E-mail：zhangboyu@dlut.edu.cn;孙凯，男，1999年出生，博士研究生。主要研究方向为杂萘联苯聚芳醚酮复合材料大尺寸板材连续成型关键技术。E-mail：sunyuan9@mail.dlut.edu.cn;穆晗，男，1981年出生，博士。主要研究方向为耐高温复合材料构件高效高稳定性表面铣削关键技术。E-mail：allenplusapple@163.com;郭贺阳，女，1999年出生，硕士研究生。主要研究方向为杂萘联苯聚芳醚酮复合材料板材低缺陷热压成型工艺。E-mail：ghyang2022@163.com;孔令满，男，2002年出生，硕士研究生。主要研究方向为杂萘联苯聚芳醚酮复合材料层间强化改性工艺。E-mail：2762117672@qq.com;蹇锡高，男，1946年出生，中国工程院院士。主要研究方向包括耐高温树脂的合成与性能、高性能树脂基复合材料、功能高分子材料等。E-mail：jian4616@dlut.edu.cn
基金资助:
国家自然科学基金(52005077)和辽宁省自然科学基金(2022-BS-090)资助项目。

Wear Prediction of Ball End Mill during the Surface Milling Processes of Modified Composites

ZHANG Boyu^1,2, SUN Kai^1,2, MU Han^3,4, GUO Heyang^1,2, KONG Lingman^1,2, JIAN Xigao^1,2

1. School of Chemical Engineering, Dalian University of Technology, Dalian 116024;
2. State Key Laboratory of Fine Chemicals, Dalian University of Technology, Dalian 116024;
3. School of Mechanical Engineering, Dalian University of Technology, Dalian 116024;
4. Aerospace Research Institute of Materials & Processing Technology, Beijing 100076

Received:2024-07-14 Revised:2025-01-09 Published:2025-08-09

摘要/Abstract

摘要： 针对斜缠改性烧蚀防热复合材料(简称“改性复合材料”)的表面铣削过程，提出了一种新的球头铣刀磨损体积预测方法。该方法不仅分别考虑了后刀面和切削刃在与工件相互作用过程中的实际应力状态，还根据表面铣削过程中的动态力热状态对磨损系数和刀具表面硬度做出了动态调整，从而全面保证了预测结果的准确性。经验证，该方法的平均预测误差小于15%。基于该方法，分析了改性复合材料表面铣削过程中的刀具磨损规律。结果表明，切削刃的磨损主要与切削刃刚度和刀-工实际接触距离有关。为降低切削刃的磨损，可通过减小刀具前、后角提升切削刃的刚度，或选择低主轴转速和高进给量减小刀-工实际接触距离。后刀面的磨损则取决于后角和工件已加工表面的回弹高度。为降低后刀面的磨损，需使用大后角刀具在高主轴转速和低进给量下进行加工。由于降低切削刃磨损与降低后刀面磨损的策略相反，综合来看，选用减小切削刃磨损的策略更有利于降低整个刀具磨损程度。

关键词: 改性复合材料, 表面铣削, 磨损预测, 磨损规律, 球头铣刀

Abstract: A novel wear prediction method of ball end mill is proposed for the surface milling processes of the heat-resistant modified composites manufactured by oblique winding and ablating processes (‘modified composites’ for short). The method not only respectively considers the actual stress states of the tool flank face and the cutting edge during the interaction with the workpiece, but also dynamically adjusts the wear coefficient and the tool surface hardness according to the dynamic state of force and temperature in the surface milling process. Through these ways, the accuracy of prediction results can be guaranteed completely. By experimental verification, it is found that the mean error of the prediction results is less than 15%. With the method, the tool wear law during the surface milling process of modified composites is analyzed. Results suggest that the cutting edge wear is related to rigidity of the cutting edge and the actual contact distance with the workpiece. To reduce the cutting edge wear, it is recommended to enhance the cutting edge rigidity by reducing the rake angle or the flank angle, or to reduce the actual contact distance by selecting low spindle speed or high feed rate. In terms of the flank face wear, it depends on the flank angle and the bouncing back height of the machined surface of workpiece. To reduce the flank face wear, milling the workpiece with the tool with large flank angle under high spindle speed or low feed rate is recommended. Since the strategies on reducing the cutting edge wear and reducing the flank face wear are contradictory, from a comprehensive perspective, it is suggested to adopt the strategy on reducing the cutting edge wear so that the wear extent of the whole tool can be suppressed more effectively.

Key words: modified composites, surface milling, wear prediction, wear law, ball end mil

中图分类号:

TH117

张博宇, 孙凯, 穆晗, 郭贺阳, 孔令满, 蹇锡高. 改性复合材料表面铣削过程中球头铣刀磨损预测[J]. 机械工程学报, 2025, 61(13): 231-245.

ZHANG Boyu, SUN Kai, MU Han, GUO Heyang, KONG Lingman, JIAN Xigao. Wear Prediction of Ball End Mill during the Surface Milling Processes of Modified Composites[J]. Journal of Mechanical Engineering, 2025, 61(13): 231-245.

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改性复合材料表面铣削过程中球头铣刀磨损预测

Wear Prediction of Ball End Mill during the Surface Milling Processes of Modified Composites

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