冷等离子体耦合微量润滑微铣削CFRP加工性能与机理研究

doi:10.3901/JME.2024.09.338

摘要/Abstract

摘要： 碳纤维复合材料(Carbon fiber reinforced polymer，CFRP)具有高强度、耐腐蚀、耐高温等优异性能，其结构具有各向异性和非均匀性，机械加工时易出现纤维撕裂、分层和脱粘等损伤，导致表面质量及使用性能难以满足实际需求。冷等离子体射流中富含活性粒子且宏观温度较低，能有效调控材料特性且不会造成明显损伤。提出采用冷等离子体射流调控CFRP材料的表面浸润性及力学特性，结合微量润滑(Minimum quantity lubrication，MQL)冷却介质辅助微铣削CFRP，实现高质量、低损伤加工。首先通过亲水性改性试验研究射流对CFRP表面浸润性的影响，发现射流能够在40 s内将CFRP表面接触角降低到10°以下，有效提高CFRP的浸润性。然后开展拉伸试验及单颗粒划痕试验研究射流对CFRP力学特性的影响，发现射流作用下CFRP的抗拉强度降低了约17%，同时促进了材料的脆性断裂。最后在不同冷却润滑条件下对CFRP开展微铣削试验，研究了冷等离子体射流及MQL冷却介质对材料切削加工性能的作用效果及机理；结果表明相较于干铣削，冷等离子体射流及MQL冷却介质的复合能场能作用下切削温度降低了28%，切削力降低了10%以上，表面粗糙度降低47%，有效减少已加工表面纤维脱粘、弯曲、撕裂等缺陷，在CFRP等复合材料的辅助加工中有广阔的应用前景。

关键词: 碳纤维复合材料, 微铣削, 冷等离子体射流, 微量润滑

Abstract: Carbon fiber reinforced polymer (CFRP) has excellent properties including high specific strength, good corrosion resistance and high-temperature resistance. However, the structure of CFRP is anisotropic and non-homogeneous, and it is prone to damage such as fiber tearing, delamination and debonding during mechanical processing, which makes it difficult for surface quality and performance to meet practical demands. Cold plasma jet is rich in active particles and has low macroscopic temperature, and can effectively modify material properties without causing significant damages. It is proposed to use cold plasma jet to regulate the surface wettability and mechanical properties of CFRP materials, combining minimum-quantity lubrication (MQL) cooling medium, achieving high-quality and low-damage machining of CFRP by composite energy field-assisted micro-milling. Firstly, the effect of cold plasma jet on the surface wettability of CFRP is studied by hydrophilization experiments, and it is found that the jet could reduce the contact angle of CFRP surface to less than 10° within 40 s, which effectively improved the wettability of CFRP. Then, tensile experiments and single particle scratch tests are conducted to investigate the effect of the plasma jet on the mechanical properties of CFRP, and it is found that the tensile strength of CFRP under the action of jet decreased by about 17%, while promoting the brittle fracture of the material. Finally, micro-milling experiments are conducted on CFRP under different cooling and lubrication conditions to study the effect and mechanism of cold plasma jet and MQL cooling medium on material machinability. The results show that compare with dry milling, the compound energy field energy of cold plasma jet and MQL cooling medium reduces the cutting temperature by 28%, the cutting force by more than 10%, and the surface roughness by 47%, and effectively alleviate defects of fiber debonding, bending and tearing on the machined surfaces.

Key words: carbon fiber reinforced polymer(CFRP), micro-milling, cold plasma jet, minimum quantity lubrication

中图分类号:

TB332

王帅帅, 段振景, 刘吉宇, 李育恒, 王梓恒, 周瑜阳, 刘新, 宋金龙, 孙晶. 冷等离子体耦合微量润滑微铣削CFRP加工性能与机理研究[J]. 机械工程学报, 2024, 60(9): 338-350.

WANG Shuaishuai, DUAN Zhenjing, LIU Jiyu, LI Yuheng, WANG Ziheng, ZHOU Yuyang, LIU Xin, SONG Jinlong, SUN Jing. Study on the Machining Performance and Mechanism of Cold Plasma Coupled Micro-lubrication Micro-milling CFRP[J]. Journal of Mechanical Engineering, 2024, 60(9): 338-350.

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