基于切削速度调控的CFRP/Ti叠层切削加工界面缺陷抑制工艺研究

doi:10.3901/JME.2025.07.198

摘要/Abstract

摘要： CFRP/Ti叠层是一种广泛应用于航空航天的高性能复合材料，其两相材料的切削变形行为对钻削制孔质量具有重要影响。在CFRP/Ti叠层的切削加工过程中，CFRP和Ti6Al4V之间显著的热力学性能差异极易形成CFRP-Ti界面缺陷，降低了制孔表面完整性，亟需研究其抑制方法。采用实验和有限元仿真方法研究了CFRP/Ti叠层切削加工中CFRP-Ti界面缺陷的形成机理，据此提出了一种在界面处调控切削速度来抑制界面缺陷形成的新型加工策略。首先，建立了符合真实微观结构特征的CFRP/Ti叠层切削的三维有限元仿真模型。其次，开展有限元仿真和实验揭示了两相材料的切削加工变形机理和CFRP-Ti界面缺陷形成机理。再次，分析了切削顺序和切削速度对CFRP-Ti界面的几何轮廓和缺陷形态的影响机制。最后，在CFRP-Ti界面处对CFRP和Ti6Al4V施加不同切削速度来改变其切削应力和应变分布，有效地控制了树脂基体和碳纤维的失效行为，从而降低了CFRP-Ti界面台阶和界面开裂，实现了CFRP-Ti界面缺陷的有效抑制。

关键词: CFRP/Ti叠层, 界面缺陷, 抑制工艺, 切削速度调控, 有限元仿真

Abstract: While CFRP/Ti stacks is a high performance composite material widely used in aerospace, the deformation behavior of their constituent phases significantly impacts its drilling quality. The intrinsically different deformation behavior between CFRP and Ti6Al4V results into interfacial defects formation in cutting of CFRP/Ti stacks. And how to minimize the interfacial surface step is critical for improving the machinability of CFRP/Ti stacks. In this work, a novel machining strategy of regulating cutting speed in the CFRP-Ti interface is proposed, which is effective in modulating the formation propensity of interfacial defects and promoting the machinability of CFRP/Ti stacks. Firstly, three-dimensional micromechanical finite element modeling and simulations of CFRP/Ti stacks cutting are carried out. Subsequently, finite element simulations and experiments are conducted to elucidate the formation mechanisms of interfacial defects at the CFRP-Ti interface. Furthermore, the profile of interfacial surface in CFRP/Ti stacks cutting, as well as its dependence on cutting sequence between the two constituent phases and cutting speed, are investigated. Finally, varying cutting speed-based strategy is applied to suppress the failure behaviors of matrix and fiber, as well as the transition characteristics of stress in adjacent CFRP and Ti6Al4V, which are effective in controlling the failure behaviors of resin matrix and carbon fibers, thus effectively suppressing the defects in CFRP-Ti interface.

Key words: CFRP/Ti stacks, interfacial defects, suppressing strategy, varying cutting speed, finite element simulation

中图分类号:

TH161

韩腊, 邵坤, 赵梁, 张俊杰. 基于切削速度调控的CFRP/Ti叠层切削加工界面缺陷抑制工艺研究[J]. 机械工程学报, 2025, 61(7): 198-209.

HAN La, SHAO Kun, ZHAO Liang, ZHANG Junjie. Regulating Cutting Speed-based Suppressing Strategy of Interfacial Defects in Orthogonal Cutting of CFRP/Ti Stacks[J]. Journal of Mechanical Engineering, 2025, 61(7): 198-209.

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