基于PVD涂层刀具的钛合金超声辅助铣削工艺优化及磨损机理研究

doi:10.3901/JME.2025.23.344

摘要/Abstract

摘要： 针对难加工材料钛合金切削加工过程中容易产生切削热聚集、刀具磨损等问题，影响加工表面质量和效率，提出采用物理气相沉积(PVD)涂层硬质合金刀具的超声辅助铣削工艺对钛合金进行高效高质量加工。首先，分析了超声辅助铣削刀-工界面的振动分离机理；然后，研究了转速、超声振幅等超声辅助铣削工艺参数对钛合金TA15加工表面质量的影响并对工艺参数进行了优化；最后，对比传统铣削与超声辅助铣削，研究Zr系和Ti系PVD涂层刀具在钛合金铣削过程中的磨损机理及超声辅助铣削工艺参数对钛合金加工表面质量的作用机制。实验结果表明：基于PVD涂层硬质合金刀具的超声辅助铣削工艺能实现钛合金的高效高质量加工，优化后的超声辅助铣削工艺参数为转速10 000 r/min和超声振幅3.30 μm。涂层刀具的磨损形式主要为涂层剥落、前刀面的月牙洼磨损以及后刀面的粘结、扩散和氧化磨损；此外，超声振动可减少刀具的扩散、氧化、磨粒磨损以及切削刃的微崩刃现象。与传统铣削相比，采用超声辅助铣削可降低钛合金加工表面粗糙度约15%；同时与Ti系涂层刀具相比，Zr系涂层刀具后刀面平均磨损量降低18.34%，钛合金铣削表面粗糙度0.082 m，且表面几乎无钛屑粘附。

关键词: 铣削, 超声振动, 钛合金, 磨损, 涂层刀具

Abstract: In order to address the challenges which negatively impact surface quality and efficiency encountered during the machining of difficult-to machine materials titanium alloys, such as cutting heat accumulation and tool wear, the ultrasonic-assisted milling (UAM) technology based on physical vapor deposition (PVD) coated tungsten carbide tools has been proposed for efficient and high-quality machining of titanium alloys. Firstly, the vibration separation mechanism at the tool-workpiece interface in UAM is analyzed. Subsequently, the effects of process parameters, including spindle speed and ultrasonic amplitude, on the surface quality of titanium alloy TA15 are investigated, and the process parameters are optimized. Finally, a comparative analysis is conducted between conventional milling (CM) and UAM to investigate the wear mechanisms of PVD-coated Zr-based and Ti-based tools during titaniumalloy milling, as well as the influences of UAM process parameters on the surface quality of titanium alloy. The experimental results indicate that the proposed UAM based on PVD-coated tools may realize efficient and high-quality machining of titanium alloys. The optimized process parameters of UAM are determined as the spindle speed of 10 000 r/min and the ultrasonic amplitude of 3.30 μm. The wear forms of the coated tools mainly include coating peeling, crater wear on the rake face, as well as adhesion, diffusion and oxidation wear on the flank face. Additionally, ultrasonic vibration can reduce the diffusion, oxidation, abrasive wear of the tool and the micro-chipping of the cutting edge. In comparison to CM, the adoption of UAM leads to a reduction of approximately 15% in surface roughness of titanium alloy. At the same time, compared to Ti-based coated tool, the average wear volume on the flank face of the Zr-based coated tool is reduced by 18.34%. The milled surface roughness of titanium alloy is 0.082 μm, which is hardly any adhesion of titanium chips.

Key words: milling, ultrasonic vibration, titanium alloy, wear, coated tool

中图分类号:

TH161
TG580

鲁艳军, 叶永辉, 关伟锋, 陈雨寒, 朱学明, 吴勇波. 基于PVD涂层刀具的钛合金超声辅助铣削工艺优化及磨损机理研究[J]. 机械工程学报, 2025, 61(23): 344-360.

LU Yanjun, YE Yonghui, GUAN Weifeng, CHEN Yuhan, ZHU Xueming, WU Yongbo. Process Optimization and Wear Mechanism of Ultrasonic-assisted Milling of Titanium Alloy Based on PVD-coated Tools[J]. Journal of Mechanical Engineering, 2025, 61(23): 344-360.

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