2.5D-C/SiC复合材料螺旋铣孔去除机理及表面质量研究

doi:10.3901/JME.2025.17.343

摘要/Abstract

摘要： 纤维增强陶瓷基复合材料具有出色的强度、刚度、耐腐蚀性、耐高温性和低密度等特性，能在多种恶劣环境下保持稳定的性能，螺旋铣削工艺孔加工还面临着去除机理不清、制孔质量差等问题。为了探究2.5D-C_f/SiC复合材料螺旋铣孔时的去除机理、损伤机理及表面质量影响规律，首先通过光滑粒子流体动力学(SPH)仿真模拟和螺旋铣孔试验分析了切削刃和2.5D-C_f/SiC复合材料纤维呈不同角度时的去除机理；然后通过试验揭示了2.5D-C_f/SiC复合材料制孔出入口损伤机理；最后通过单因素试验分析了螺旋铣削工艺参数对孔壁表面质量的影响规律。结果表明：2.5D-C_f/SiC复合材料在螺旋铣削过程中，碳化硅基体主要发生脆性破碎且有裂纹产生，以碎屑方式去除；0°方向纤维存在纤维断裂、纤维磨损、纤维拔除损伤，45°方向纤维产生纤维断裂和纤维露头现象，90°方向纤维有纤维断裂、纤维拔除现象产生，135°方向纤维存在纤维拔除、纤维断裂和露头现象，针刺方向纤维与0°方向纤维损伤类似；界面相区域产生界面脱粘失效；孔出入口损伤以毛刺和崩边损伤为主；表面质量随着主轴转速的提高而改善，随着螺距和公转转速的增加而变差。当主轴转速由1 000 r/min提高到4 000 r/min后，孔壁表面粗糙度降低了23.76%，当螺距从0.1 mm增加到0.4 mm时，孔壁表面粗糙度提高了38.69%，当公转转速从5 r/min增加到20 r/min时，孔壁表面粗糙度增加了8.1%。本研究为螺旋铣削2.5D-C_f/SiC复合材料高质量制孔加工提供了重要参考。

关键词: 螺旋铣削, 材料去除机理, 制孔表面质量, SPH仿真, 2.5D-C_f/SiC

Abstract: Fiber reinforced ceramic matrix composites have excellent strength, stiffness, corrosion resistance, high temperature resistance and low density, and can maintain stable performance in a variety of harsh environments. Helical milling process also faces problems such as unclear removal mechanism and poor hole quality. In order to investigate the removal mechanism, damage mechanism and surface quality influence law of 2.5D-C_f/SiC composite during helical hole milling, the removal mechanism of 2.5D-C_f/SiC composite fiber at different angles is analyzed by smooth particle fluid dynamics (SPH) simulation and helical hole milling test. Then the damage mechanism of 2.5D-C_f/SiC composite is revealed through experiments. Finally, the influence of helical milling parameters on the surface quality of hole wall is analyzed by single factor test. The results show that in the helical milling process of 2.5D-C_f/SiC composites, the SIC matrix is mainly brittle and cracked, which is removed by debris. Fiber breakage, fiber wear, fiber pulling damage occurred in fibers at 0° direction, fiber breakage and fiber outcrop occurred in fibers at 45° direction, fiber breakage and fiber pulling out occurred in fibers at 90° direction, fiber pulling out, fiber breakage and fiber outcrop occurred in fibers at 135° direction, and fiber damage at acupuncture direction was similar to fiber damage at 0° direction. The interface phase region produces interface debonding failure. Burr damage and edge collapse damage are the main damage at the entrance and exit of the hole. The surface quality improves with the increase of spindle speed, and deteriorates with the increase of pitch and revolution speed. When the spindle speed is increased from 1 000 r/min to 4 000 r/min, the surface roughness of the hole wall is reduced by 23.76%; when the pitch is increased from 0.1 mm to 0.4 mm, the surface roughness of the hole wall is increased by 38.69%; when the revolution speed is increased from 5 r/min to 20 r/min, the surface roughness of the hole wall increased by 8.1%. This study provides an important reference for helical milling of 2.5D-C_f/SiC composites with high quality hole making.

Key words: helical milling, material removal mechanism, hole surface quality, SPH simulation, 2.5D-C_f/SiC

中图分类号:

TB332

周云光, 逯一泽, 邹忌, 刘记, 马廉洁, 李明, 巩亚东. 2.5D-C/SiC复合材料螺旋铣孔去除机理及表面质量研究[J]. 机械工程学报, 2025, 61(17): 343-359.

ZHOU Yunguang, LU Yize, ZOU Ji, LIU Ji, MA Lianjie, LI Ming, GONG Yadong. Study on the Removal Mechanism and Surface Quality of 2.5D-C/SiC Composites by Helical Milling[J]. Journal of Mechanical Engineering, 2025, 61(17): 343-359.

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