基于运动学及力热分析的CFRP超声振动辅助螺旋铣孔质量影响机制

doi:10.3901/JME.2021.01.199

机械工程学报 ›› 2021, Vol. 57 ›› Issue (1): 199-209.doi: 10.3901/JME.2021.01.199

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基于运动学及力热分析的CFRP超声振动辅助螺旋铣孔质量影响机制

陈光^1,2, 刘见¹, 戈家影¹, 秦旭达^1,2, 邹云鹤¹, 任成祖^1,2

1. 天津大学教育部机构理论与设备设计重点实验室天津 300354;
2. 天津大学天津市装备设计与制造技术重点实验室天津 300354

收稿日期:2020-02-05 修回日期:2020-07-13 出版日期:2021-01-05 发布日期:2021-02-06
通讯作者: 陈光(通信作者),男,1983年出生,博士,副教授,博士研究生导师。主要研究方向为航空材料切削机理、超声振动辅助切削技术。E-mail:guangchen@tju.edu.cn
基金资助:
国家自然科学基金资助项目（51575384、51675369）。

Experimental Study on Ultrasonic Vibration Helical Milling of CFRP Based on Kinematic and Thermal-mechanical Analysis

CHEN Guang^1,2, LIU Jian¹, GE Jiaying¹, QIN Xuda^1,2, ZOU Yunhe¹, REN Chengzu^1,2

1. Key Laboratory of Mechanism Theory and Equipment Design of Ministry of Education, Tianjin University, Tianjin 300354;
2. Tianjin Key Laboratory of Equipment Design and Manufacturing Technology, Tianjin University, Tianjin 300354

Received:2020-02-05 Revised:2020-07-13 Online:2021-01-05 Published:2021-02-06

摘要/Abstract

摘要： 碳纤维增强复合材料（Carbon fiber reinforced polymer/plastic，CFRP）因其较高的比强度、耐腐蚀性、耐疲劳性等优异性能，被广泛应用于航空航天领域，但作为各向异性的难加工材料，制孔过程易产生损伤。针对CFRP超声振动辅助螺旋铣孔质量为研究内容，首先建立了轴向超声辅助螺旋铣孔的运动学方程，对与孔壁接触的侧刃的切削轨迹、速度、超声辅助螺旋铣孔过程侧刃的有效前角进行了求解。分析了有无超声振动条件下CFRP孔表面的纤维断裂及材料去除机理，在切削角度为0～45°范围内，螺旋铣纤维主要承受拉伸应力，而超声辅助螺旋铣条件下纤维承受变向剪切作用，纤维易断裂且与基体脱粘现象显著降低。此外，研究了工艺参数（轴转速、螺距、切向每齿进给量）对CFRP超声振动辅助螺旋铣孔切削力和切削温度的影响规律。结合切削力、热、切削刃与刀具的相对位移、运动速度及有效前角的变化，分析了工艺参数对毛刺、分层损伤及出入口孔径的影响机制。研究表明由于超声振动的存在，工艺参数影响刀具与工件的接触及分离属性、刀具的有效前角，从而影响切削过程中的力、热的变化，进而影响制孔质量。

关键词: CFRP复合材料, 超声振动, 螺旋铣孔, 工艺参数, 制孔质量

Abstract: Carbon fiber reinforced polymer/plastic (CFRP) composites are widely used in aerospace industry because of high specific strength, corrosion resistance, fatigue resistance and other excellent properties. However, as typical anisotropic difficult-to-cut material, damage easily occurred in the hole-making of CFRP. This work focused on the quality of hole-making process, kinematic equations for ultrasonic vibration assisted helical milling (UVHM) are established, and the movement trajectory, cutting speed and equivalent rake angle of peripheral edge are studied. Fiber damage and material removal mechanism with or without ultrasonic vibration in HM is investigated. It is found that within the range of 0-45° cutting angle, fibers mainly bear the tensile stress in helical milling, while in UVHM, fibers bear mainly shearing stress with variable directions, which make the fiber fracture easily and the debonding between the fiber and resin is reduced accordingly. The effects of spindle speed, axial and tangential feeds on the cutting temperature and forces in UVHM are also investigated. Based on the variation of cutting force, temperature, the relative movement, speed between the cutting edge and fibers, and the equivalent rake angle, the influence mechanism of process parameters on the bur formation, delamination, and hole diameter was investigated. Due to ultrasonic vibration, the processing parameters affect the tool-workpiece contact behaviors, tool equivalent rake angle, leading to the variation of outting heat, forces, and finally, the quality of machined holes.

Key words: CFRP composites, ultrasonic vibration, helical milling, process parameters, hole quality

中图分类号:

TG156

陈光, 刘见, 戈家影, 秦旭达, 邹云鹤, 任成祖. 基于运动学及力热分析的CFRP超声振动辅助螺旋铣孔质量影响机制[J]. 机械工程学报, 2021, 57(1): 199-209.

CHEN Guang, LIU Jian, GE Jiaying, QIN Xuda, ZOU Yunhe, REN Chengzu. Experimental Study on Ultrasonic Vibration Helical Milling of CFRP Based on Kinematic and Thermal-mechanical Analysis[J]. Journal of Mechanical Engineering, 2021, 57(1): 199-209.

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基于运动学及力热分析的CFRP超声振动辅助螺旋铣孔质量影响机制

Experimental Study on Ultrasonic Vibration Helical Milling of CFRP Based on Kinematic and Thermal-mechanical Analysis

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