刀具结构对钛合金波动式超声制孔的表面完整性和疲劳性能影响研究

doi:10.3901/JME.260702

摘要/Abstract

摘要： 针对飞机紧固孔高质高强加工需求，建立了波动式超声制孔运动学理论模型，揭示了横向椭圆超声振动在降低切削力和提高表面强化效能方面的作用机理。以钛合金Ti-6Al-4V为试验材料，研究了铰刀刀具结构在孔强化效能方面的作用。结果表明：无论是铰刀主切削刃还是修光刃，增加倒棱角度、减小后角以及增大刃口钝圆半径均可有效增加孔表面残余压应力。与常规刀具普通制孔相比，优化后的六齿多因素钝化铰刀在波动式超声制孔时可以使表面显微硬度增加了22.6%～26.2%，表面残余压应力增加了114.24%～164.58%，塑性变形层厚度增加了3.7倍，疲劳寿命提高了156.18%，疲劳源从孔口倒角近表面区域转移为孔内亚表面。波动式超声制孔方法结合刀具结构优化可以在飞机紧固孔加工中同步实现精加工和深强化，为飞机精强一体化制孔提供了新的原理和方法。

关键词: 刀具结构, 波动式超声制孔, 表面质量, 强化效能, 疲劳寿命

Abstract: In the need of high-quality holes, a kinematic theoretical model of ultrasonic peening drilling (UPD) is established, revealing the mechanism of transverse ultrasonic vibration in improving surface quality. The influence of the tool structure on hole strengthening is studied. The results indicate that increasing the chamfer angle, reducing the relief angle, and increasing the blunt radius of the cutting edge can effectively increase the residual compressive stress, whether it is the main cutting edge or the smoothed edge of the reamer. Compared with ordinary cutting tool in CD, the optimized six-tooth multi-factor blunt reamer in UPD can increase surface microhardness by 22.6% to 26.2%, residual compressive stress by 114.24% to 164.58%, plastic deformation layer thickness by 3.7 times and fatigue life by 156.18%. The fatigue source shifts from the chamfer area of the hole surface to the hole subsurface. Therefore, the combination of UPD method and tool structure optimization can simultaneously achieve precision machining and deep strengthening, providing a new principle for integrated precision and strengthening hole-making of aircraft.

Key words: tool structure, transverse elliptical ultrasonic vibration, surface quality, strengthening effect, fatigue life

中图分类号:

V261

孙哲飞, 张德远, 耿大喜, 孟繁星, 姜兴刚. 刀具结构对钛合金波动式超声制孔的表面完整性和疲劳性能影响研究[J]. 机械工程学报, 2026, 62(13): 386-398.

SUN Zhefei, ZHANG Deyuan, GENG Daxi, MENG Fanxing, JIANG Xinggang. The Influence of Tool Structure on Surface Integrity and Fatigue Life in Ultrasonic Peening Drilling Titanium Holes[J]. Journal of Mechanical Engineering, 2026, 62(13): 386-398.

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链接本文: http://www.cjmenet.com.cn/CN/10.3901/JME.260702

http://www.cjmenet.com.cn/CN/Y2026/V62/I13/386

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