超声辅助钻削1J22软磁合金表面完整性研究

doi:10.3901/JME.2025.01.345

摘要/Abstract

摘要： 随着电磁元器件性能要求的逐渐提高，饱和磁感应强度高、饱和磁致伸缩系数大、居里温度高的1J22软磁合金获得了广泛关注，被认为是航空航天领域中电磁元器件的高性能材料。但1J22软磁合金的加工性能较差，钻削加工后构件的表面完整性会显著降低磁场均匀性和服役稳定性，严重阻碍了其大规模的工程应用。针对以上问题，采用超声辅助钻削加工技术对1J22软磁合金进行制孔加工，通过光学显微镜、扫描电镜、透射电镜和显微硬度仪等仪器，并结合有限元仿真技术，分析了超声振动和钻削参数对1J22软磁合金孔表面形貌与粗糙度、微观组织、硬化程度和棱边质量的影响，揭示了超声振动作用的影响机理。研究结果表明，相比于普通钻削，超声辅助钻削能够降低孔壁表面粗糙度21%；超声振动作用可以使钻削过程中切屑和孔壁区域更易分离，减小孔壁区域的塑性变形，使微观组织改变的影响区域减小，具体表现在晶粒细化层宽度减小40%、加工硬化层深度减小6%；但超声辅助钻削过程中较高的瞬时轴向力所带来的冲击作用会使孔出口处的崩边面积有所增加。研究为1J22软磁合金高表面完整性孔的加工提供理论指导。

关键词: 1J22软磁合金, 超声辅助钻削, 表面完整性, 表面形貌与粗糙度, 微观组织, 加工硬化, 崩边, 有限元仿真

Abstract: As the performance requirements of electromagnetic components gradually increase, 1J22 soft magnetic alloy has attracted extensive interest due to its high saturation magnetic induction strength, high saturation magnetostriction coefficient and high Curie temperature. Consequently, this alloy is regarded as a material capable of significantly improving the performance of electromagnetic components in the aerospace. However, the machinability of 1J22 soft magnetic alloy is poor. The surface integrity of the components after drilling will seriously affect the magnetic field uniformity and service stability, which seriously hinders its application. Ultrasonic assisted drilling technology is used in order to solve the hole-making problem of 1J22 soft magnetic alloy. Combining experimental testing with finite element method, the surface integrity was characterized using optical microscopy, scanning electron microscopy, transmission electron microscopy, and microhardness tester. The effects of ultrasonic vibration and drilling parameters on the surface morphology, roughness, microstructure, hardening degree, and edge quality of 1J22 soft magnetic alloy holes were concluded and the in fluence mechanism of ultrasonic vibration was revealed. It is found that, compared to conventional drilling, the applying of ultrasonic assisted drilling can decrease the surface roughness by 21%. The ultrasonic assisted drilling can also facilitate the separation of chips and hole wall area, reducing plastic deformation in the hole wall region and minimizing the affected area of microstructural changes. Specifically, after ultrasonic assisted drilling, there is a 40% reduction in grain refinement layer width and a 6% decrease in the depth of the work-hardened layer. On the contrary, the higher instantaneous axial force can lead to an increase in the area of edge chipping at the hole exit. The research provides theoretical guidance for the machining of high surface integrity holes in 1J22 soft magnetic alloy.

Key words: soft magnetic alloy 1J22, ultrasonic assisted drilling, surface integrity, surface morphology and roughness, micro-structure, work hardening, exit chipping, finite element method

中图分类号:

TG527

隗雨欣, 宋洪侠, 张园, 薛冠鸣, 康仁科, 鲍岩, 董志刚. 超声辅助钻削1J22软磁合金表面完整性研究[J]. 机械工程学报, 2025, 61(1): 345-359.

WEI Yuxin, SONG Hongxia, ZHANG Yuan, XUE Guanming, KANG Renke, BAO Yan, DONG Zhigang. Surface Integrity of Ultrasonic Assisted Drilling Soft Magnetic Alloy 1J22[J]. Journal of Mechanical Engineering, 2025, 61(1): 345-359.

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