高深径比CFRP微孔变入射角激光加工试验研究

doi:10.3901/JME.2025.21.427

摘要/Abstract

摘要： 碳纤维增强复合材料(Carbon fiber reinforced plastic，CFRP)拥有比刚度和强度高、热稳定性和耐腐蚀性好等优异特性，在航空航天、医疗和国防等领域应用广泛。然而，CFRP中纤维和树脂基体的材料特性差异导致传统方法难以加工高深径比CFRP微孔。为此，设计搭建变入射角(Angles of incidence，AOI)超快激光加工系统，研究该系统加工高深径比CFRP微孔的能力，系统分析激光脉冲能量、扫描速度和AOI对直径200 μm、深径比10:1的CFRP微孔加工质量的影响。结果表明，激光脉冲能量和扫描速度显著影响微孔入口和出口热影响区(Heat-affected zone，HAZ)大小，AOI则显著影响微孔锥度；变AOI的螺旋扫描加工策略可有效解决固定AOI在聚焦深度变化时的能量分布不均问题，极大减小微孔锥度，甚至可实现负锥微孔加工；合理的修边和清扫策略可以有效减小侧壁粗糙度，最小Ra<0.8 μm。最后，通过加工2×3的微孔阵列，验证工艺参数优化的有效性，表明变入射角激光在高深径比CFRP微孔加工方面的巨大潜力。

关键词: 激光加工, 碳纤维增强复合材料, 微孔, 变入射角

Abstract: Carbon fiber reinforced plastic (CFRP) composites possess exceptional properties such as high specific stiffness and strength, superior thermal stability, and excellent corrosion resistance, making them widely used in fields such as aerospace, medicine, and defense. However, the inherent differences in material characteristics between the fibers and the resin matrix in CFRP present significant challenges for conventional methods to effectively process high aspect ratio micro-holes. To address this issue, an ultrafast laser processing system with adjustable angles of incidence (AOI) is designed and constructed to investigate its capability in processing high aspect ratio micro-holes in CFRP. A comprehensive analysis is conducted to examine the influence of laser pulse energy, scanning speed, and AOI on the machining quality of CFRP micro-holes with a diameter of 200 μm and an aspect ratio of 10:1. The results indicate that laser pulse energy and scanning speed have a significant impact on the size of the heat-affected zone (HAZ) at the micro-hole entrance and exit, while AOI substantially affects the taper of the micro-holes. A spiral scanning strategy with variable AOI effectively addresses the issue of uneven energy distribution caused by changes in focal depth when using a fixed AOI, significantly reducing the taper of the micro-holes, and even enabling the fabrication of negative taper micro-holes. Furthermore, the implementation of appropriate trimming and cleaning strategies effectively reduces sidewall roughness, achieving a minimum surface roughness (Ra) of less than 0.8 μm. Finally, the effectiveness of optimized process parameters is validated by machining a 2×3 micro-hole array, demonstrating the tremendous potential of variable AOI laser processing in the fabrication of high aspect ratio CFRP micro-holes.

Key words: laser processing, CFRP, micro-holes, variable angles-of-incidence

中图分类号:

TN249

马尧, 王禹祺, 徐文俊, 崔家荣, 李军, 罗涛, 周伟. 高深径比CFRP微孔变入射角激光加工试验研究[J]. 机械工程学报, 2025, 61(21): 427-436.

MA Yao, WANG Yuqi, XU Wenjun, CUI Jiarong, LI Jun, LUO Tao, ZHOU Wei. Experimental Study on Drilling High Aspect Ratio Micro-holes in CFRP Using Laser with Variable Angles of Incidence[J]. Journal of Mechanical Engineering, 2025, 61(21): 427-436.

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