超声振动铣削加工石墨材料去除机理与加工表面质量评价

doi:10.3901/JME.2024.09.086

机械工程学报 ›› 2024, Vol. 60 ›› Issue (9): 86-96.doi: 10.3901/JME.2024.09.086

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超声振动铣削加工石墨材料去除机理与加工表面质量评价

陈守峰¹, 王成勇¹, 李伟秋², 丁峰¹, 卢耀安¹, 周玉海³

1. 广东工业大学广东省微创手术器械设计与精密制造重点实验室广州 510006;
2. 汇专科技集团股份有限公司广州 510700;
3. 广铁职业技术学院广州 510430

收稿日期:2023-05-02 修回日期:2023-09-20 出版日期:2024-05-05 发布日期:2024-06-18
作者简介:陈守峰，男， 1992 年出生，博士研究生。主要研究方向为硬脆材料超声振动辅助加工。E-mail： 2603195992@qq.com;王成勇(通信作者)，男， 1964 年出生，博士，教授，博士研究生导师。主要研究方向为难加工金属、非金属、高分子、复合材料等的高速高性能绿色加工理论、刀具、工艺与装备。E-mail： cywang@gdut.edu.cn
基金资助:
佛山市科技创新(1920001000818)和广东省重点领域研发计划(2020B090924005)资助项目。

Material Removal Mechanism and Surface Quality Evaluation of Graphite Ultrasonic Vibration Milling

CHEN Shoufeng¹, WANG Chengyong¹, LI Weiqiu², DING Feng¹, LU Yaoan¹, ZHOU Yuhai³

1. Guangdong Provincial Key Laboratory of Minimally Invasive Surgical Instruments and Manufacturing Technology, Guangdong University of Technology, Guangzhou 510006;
2. Conprofe Technology Group Co., Ltd, Guangzhou 510700;
3. Guangzhou Railway Polytechnic, Guangzhou 510430

Received:2023-05-02 Revised:2023-09-20 Online:2024-05-05 Published:2024-06-18

摘要/Abstract

摘要： 石墨模具铣削加工过程中存在严重的表面破碎问题，超声振动辅助加工能够显著减少表面破碎，提高加工质量。然而，目前缺少超声振动辅助铣削石墨材料的材料去除机理和加工质量评价相关研究。通过超声振动辅助铣削实验，研究了石墨材料超声振动辅助铣削去除机理和加工表面质量影响因素；分析了超声振动辅助对切削力、声发射信号强度、切屑和表面形貌特征的影响；探究了加工工艺参数对表面粗糙度的影响规律。结果表明，石墨材料铣削加工材料去除机制主要分为微破碎去除和大块破碎去除两类。超声振动辅助能够提高材料微破碎去除机制比例，提高加工质量，同时降低切削力约25%和声发射信号强度。通过工艺参数实验发现，超声振动辅助铣削条件下，降低径向切削深度和每齿进给量能够降低表面粗糙度2倍以上。选择合适的超声振幅有助于抑制表面破碎和提高加工表面质量，但是增大切削速度会削弱超声振动作用，过大的超声振幅也会导致表面质量变差。综上，超声振动辅助对抑制石墨铣削加工表面破碎具有明显效果，为进一步解决石墨加工表面破碎问题提供指导。

关键词: 超声振动, 铣削, 石墨材料, 去除机理, 表面质量

Abstract: Surface fragmentation often occurs during the milling process of graphite mold. Ultrasonic vibration assisted machining can improve surface fragmentation and machining quality. However, currently, there is a lack of the research on the material removal mechanism and machining quality evaluation of ultrasonic vibration assisted milling of graphite materials have not been studied. Through ultrasonic vibration assisted milling experiments, the removal mechanism of graphite materials during ultrasonic vibration assisted milling and the influencing factors on the quality of machined surfaces are investigated.The effects of ultrasonic vibration assistance on cutting force, acoustic emission signal strength, chip and surface morphology characteristics are analyzed. And the influence of processing parameters on surface roughness is explored. The results indicate that the material removal mechanisms during graphite material milling can be divided into micro crushing removal and large scale crushing removal. Ultrasonic vibration assistance can improve the proportion of micro crushing removal mechanism, improve machining quality, and reduce cutting force by about 25% and acoustic emission signal strength. Through process parameter experiments, it is found that under ultrasonic vibration assisted milling conditions, reducing the radial cutting depth and feed rate per tooth can reduce surface roughness by more than twice. Choosing an appropriate ultrasonic amplitude can help suppress surface fragmentation and improve the quality of the processed surface, but increasing the cutting speed can weaken the effect of ultrasonic vibration, and excessive ultrasonic amplitude can also lead to poor surface quality. In summary, ultrasonic vibration assistance has a significant effect on suppressing surface fragmentation in graphite milling, providing guidance for further solving the problem of surface fragmentation in graphite machining.

Key words: ultrasonic vibration, milling, graphite material, removal mechanism, surface quality

中图分类号:

TG156

陈守峰, 王成勇, 李伟秋, 丁峰, 卢耀安, 周玉海. 超声振动铣削加工石墨材料去除机理与加工表面质量评价[J]. 机械工程学报, 2024, 60(9): 86-96.

CHEN Shoufeng, WANG Chengyong, LI Weiqiu, DING Feng, LU Yaoan, ZHOU Yuhai. Material Removal Mechanism and Surface Quality Evaluation of Graphite Ultrasonic Vibration Milling[J]. Journal of Mechanical Engineering, 2024, 60(9): 86-96.

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超声振动铣削加工石墨材料去除机理与加工表面质量评价

Material Removal Mechanism and Surface Quality Evaluation of Graphite Ultrasonic Vibration Milling

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