微切削加工单位切削力及表面加工质量的尺寸效应研究
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摘要
随着微电子工业、医疗设备、生物工程、国防工业和航空航天技术的不断发展,毫米或微米级别的微小零部件的形状越来越复杂,要其实现的功能越来越多,材料种类越来越丰富,对其可靠性要求越来越高。不同于刻蚀技术、薄膜技术和LIGA技术,微切削加工技术可以快速高精度低成本地制造复杂三维微小零件,有着广阔的应用前景。最小切削厚度、单位切削力的尺寸效应和表面完整性的尺寸效应是微切削加工中的主要现象,深入研究微切削加工过程中的材料变形机理,有助于理解微切削过程中的特有现象,提高微切削加工质量。
微切削加工中,随着切削厚度的减小,切削刃刃口圆弧半径和切削厚度在同一数量级,切削厚度和切削刃刃口圆弧半径的比值成为影响微切削过程的重要因素。文章基于滑移线场法分析微切削中工件材料的变形,研究单位切削力尺寸效应的产生机理,阐述单位切削力对表面完整性、毛刺高度的尺寸效应的影响机理,建立微铣削单位切削力模型,分析微铣削顶端毛刺的影响因素及影响规律。
首先,基于滑移线场理论建立考虑切削刃刃口圆弧的微切削力模型,计算不同切削厚度和切削刃刃口圆弧半径比值条件下的直角微切削力和单位切削力,并进行实验验证。研究发现：微切削力随着切削厚度和切削刃刃口圆弧半径比值的减小而逐渐减小,而单位切削力逐渐增大。收集直角微切削产生的切屑并测量变形后的切屑厚度,发现在刀具前刀面的堆积作用下切屑变形系数表现出明显的尺寸效应。随着切削厚度的减小,工件材料主剪切区的剪切应变、剪切应变率和剪切温度都逐渐增大,表现出明显的尺寸效应；随着切削厚度的减小,塑性应变梯度强化效应越来越大,由于温度的软化效应,工件材料主剪切区的流动应力越来越小,二者共同导致塑性应变梯度硬化系数越来越大；由于切削刃刃口圆弧的存在,使得微切削的变形路径增长,相对切削长度表现出明显的尺寸效应现象；同时切削刃刃口圆弧对前下方的工件有很强的挤压作用,这也是影响微切削单位切削力的重要因素。
其次,基于切削刃刃口圆弧附近材料的单位切削力变化分析微车削加工表面完整性尺寸效应的产生机理。随着切削厚度和刃口圆弧半径比值的减小,切削刃刃口圆弧附近工件材料的单位切削力逐渐增大,材料的流动性逐渐增强,工件材料发生侧流并在刀具的前刀面和后刀面附近堆积,当前、后刀面堆积的高度与进给量达到平衡时,获得最佳的微车削表面粗糙度。微切削加工中,微刀具以较大的有效负前角挤压-剪切工件材料,已加工表面先受到前刀面的挤压,后受到后刀面的挤压。微切削中已加工表面的显微硬度随着切削厚度和刃口圆弧半径比值的减小先减小后增大,当前、后刀面作用的应力相等时,已加工表面的显微硬度值最小。
然后,分析切削厚度和切削刃刃口圆弧半径的比值对微切削毛刺高度的影响。切削刃刃口圆弧附近的工件材料在微刀具刃口圆弧挤压作用下发生侧流,形成泊松毛刺(切入毛刺和两侧毛刺)。当切削厚度小于切削刃刃口圆弧半径时,泊松毛刺的高度随着切削厚度和切削刃刃口圆弧半径的比值减小而急剧增大；当切削厚度大于切削刃刃口圆弧半径时,由于切削刃刃口圆弧附近的压力恒定不变,泊松毛刺的高度没有变化。切出毛刺是由微切削刀具推挤残留在工件边缘的切屑形成。由于单位切削力尺寸效应的影响,微切削中残留部分毛刺的高度增大。微切削的切出毛刺是一种新型卷曲毛刺,卷曲半径随着切削厚度和切削刃刃口圆弧半径的比值先减小后增大,在切削厚度和切削刃刃口圆弧半径的比值等于1时达到最小,导致切出毛刺的总高度表现出明显的尺寸效应。
最后,分析工件材料微铣削去除过程,建立包含尺寸效应的微铣削单位切削力模型,分析铣削参数(每齿进给量和轴向切削深度)、刀具参数(微铣刀直径和螺旋角角度)和铣削方式对单位切削力的影响。微铣削由于刀具螺旋角的影响使得切削方式发生转变,材料的去除机理不同于二维直角微切削。随着每齿进给量的减小,瞬时切削厚度和切削刃刃口圆弧半径的比值减小,三维单位切削力随着每齿进给量的减小而增大；随着轴向切削深度的减小,位于切入角度和切出角度区域的切削刃比例增加,三维单位切削力缓慢增大；随着微铣刀螺旋角的减小,径向和切向单位切削力逐渐增大,轴向的单位切削力逐渐减小；随着微铣刀直径的减小,三维单位切削力逐渐缓慢减小,变化趋势不明显；随着径向切削宽度的减小,径向的单位切削力逐渐增大,逆铣方式大于顺铣方式,切向的单位切削力逐渐减小,逆铣方式小于顺铣方式,轴向的单位切削力逐渐增大,两种方式差别不大。通过微铣削试验分析铣削参数、刀具参数和铣削方式对微铣削顶端毛刺的影响。由于毛刺卷曲半径的影响,顶端毛刺高度随着每齿进给量减小先减小后增大；由于参与切削的切削刃长度缩短,顶端毛刺高度随着轴向切深的减小而逐渐减小；当切削刃刃口圆弧半径和每齿进给量相等时,顶端毛刺高度最小；由于排屑能力减弱,顶端毛刺高度随着螺旋角的减小逐渐增大。
本研究得到国家自然科学基金重点项目“基于多重尺寸效应耦合的超硬微铣刀设计理论和制造技术(50935003)”和山东省自然科学杰出青年基金“超高速微细切削加工变形学研究(JQ200918)”资助。
With the development of microelectronics industry, modern medical equipment, biological engineering, national defense industry and aerospace technology, the micro parts in the range of millimeter or micron meter are demanded more complex shape, more functions, more kinds of material, higher reliability. Micro machining technology is different from etching technology, thin-film technology and LIGA technology, and it can create a complicated three-dimensional small part of different materials quickly with higher precision at lower cost, then micro cutting has a promising application prospect. Micro cutting appears some characteristics different from macro cutting such as minimum uncut chip thickness, size effect of specific cutting force and size effect of surface integrity. Investigation on the mechanism of workpiece deform is helpful to understanding the peculiar phenomenon of micro cutting process, and improve the quality of micro parts.
The extrusion effect of the cutting edge on the workpiece cannot be neglected in micro cutting and the ratio of uncut chip thickness to cutting edge radius becomes an important parameters. The deformation of workpiece is analyzed based on the slip-line field. The mechanism of size effect of specific cutting force and the effect of specific cutting force on the surface roughness and burr height are investigated. A specific milling force model of micro flat end milling is established and the factors and mechanism of top side burr in micro flat end milling experiments are analyzed.
Firstly, a deformation model is established considering the round cutting edge based on the slip-line fields. The micro orthogonal cutting forces are calculated and validated with different ratios of uncut thickness to cutting edge radius. The cutting force decreases with the ratio of uncut chip thickness to cutting edge radius decreasing, the specific cutting force increases with the decrease of uncut chip thickness to cutting edge radius. Collecting and measuring the deformed chip in micro orthogonal cutting, the deformation coefficient shows the size effect due to the pile up of the workpiece in the front of the cutting edge. With the decrease of the ratio of uncut chip thickness to cutting edge radius, the shear strain, shear strain rate, and shear temperature in the primary shear zone increases and shows the size effect phenomenon. The shear flow stress in the primary shear stress decreases due to the softening effect of the shear temperature. The plasticity strain gradient strengthening coefficient increases due to the effect of the plasticity strain gradient and the shear flow stress in the primary shear zone. The deformation path increases due to the round cutting edge and the relative cutting shows size effect phenomenon.
Secondly, the mechanism of size effect of surface integrity is investigated based on the variation of specific cutting force around the corner. Specific cutting force and the flow ability of workpiece around the comer increases when the ratio of uncut chip thickness to corner radius. The side flow takes place and the workpiece piles up in front of the cutting edge and behind the cutting edge. The best surface roughness will be got when the pile-up height of rake, flank face and feed rate reaches a balance. The cutting edge of cutting tool extrudes and shears the workpiece with the round cutting edge. The machined surface is first extruded by the rake face and then ploughed by the flank face. The micro hardness decreases first and then increases when the ratio of uncut chip thickness to cutting edge radius decreases, and it reaches the bottom when the stress around the rake face equals that of flank face.
Thirdly, the effect of specific cutting force on the burr height is studied. Side flow takes place when the tool extrudes the workpiece and the Poisson burr forms (entrance burr and side burr). The Poisson burr height increases with the decrease of the ratio of uncut chip thickness to cutting edge radius when the uncut chip thickness is smaller than the cutting edge radius. The Poisson burr height is stable because of the stable specific cutting force around the cutting edge when the uncut chip thickness is larger than the cutting edge radius. The tool extrudes the chip on the edge and the exit burr forms. The exit burr height will increase due to the effect of size effect of specific cutting force. The exit burr is a curled burr and different from that of macro cutting. The curled radius decreases first, and then increases with the decrease of the ratio of uncut chip thickness to cutting edge radius.
Finally, a specific cutting force model is established of micro flat end milling including the size effect of specific cutting force, the factors of milling parameters such as feed per tooth, axial depth of cut, tool parameters such as tool diameter, helical angle, milling method such as up milling, down milling on specific cutting force are analyzed. The milling process is different from orthogonal cutting of two dimensions due to the influence of helical angle. The specific cutting forces in the three directions increase with the decrease of the feed per tooth due the size effect of specific cutting force. The specific cutting forces in the three directions increase slowly due to the increase of cutting edge in the entrance and exit area when the axial depth of cut decreases. The specific cutting forces in the ox, oy directions increase with the decrease of the helical angle, while the specific milling force in the oz direction decrease. The specific cutting forces decrease in the three directions with the decrease of the tool diameter. The specific cutting force increases with the decrease of the radial cutting width in the ox direction, and the specific cutting force in the up milling is larger than that of down milling. The specific cutting force decreases with the decrease of the radial cutting width in the oy direction, and the specific cutting force in the up milling is smaller than that of down milling. The specific cutting force increases with the decrease of the radial cutting width in the oz direction, and the specific cutting force in the up milling is in the same level with that of down milling. The factors of milling parameters such as feed per tooth, axial depth of cut, tool parameters such as cutting edge radius, helical angle on top side burr are analyzed in micro flat end milling. The height of top side burr shows size effect with the decrease of the feed per tooth. The top side burr height decreases with the decrease of axial depth of cut due to the shortening of the cutting edge. The height of top side burr reaches the minimum when the cutting edge radius is equal to the feed per tooth. The top side burr height increases with the decrease of the helical angle due to poor clearance.
This work is sponsored by the National Natural Science Foundation of China (Grant No.50905003) and Foundation of Shandong Province of China for Distinguished Young Scholars (Grant No. JQ200918) for financial supports.
微切削加工中,随着切削厚度的减小,切削刃刃口圆弧半径和切削厚度在同一数量级,切削厚度和切削刃刃口圆弧半径的比值成为影响微切削过程的重要因素。文章基于滑移线场法分析微切削中工件材料的变形,研究单位切削力尺寸效应的产生机理,阐述单位切削力对表面完整性、毛刺高度的尺寸效应的影响机理,建立微铣削单位切削力模型,分析微铣削顶端毛刺的影响因素及影响规律。
首先,基于滑移线场理论建立考虑切削刃刃口圆弧的微切削力模型,计算不同切削厚度和切削刃刃口圆弧半径比值条件下的直角微切削力和单位切削力,并进行实验验证。研究发现：微切削力随着切削厚度和切削刃刃口圆弧半径比值的减小而逐渐减小,而单位切削力逐渐增大。收集直角微切削产生的切屑并测量变形后的切屑厚度,发现在刀具前刀面的堆积作用下切屑变形系数表现出明显的尺寸效应。随着切削厚度的减小,工件材料主剪切区的剪切应变、剪切应变率和剪切温度都逐渐增大,表现出明显的尺寸效应；随着切削厚度的减小,塑性应变梯度强化效应越来越大,由于温度的软化效应,工件材料主剪切区的流动应力越来越小,二者共同导致塑性应变梯度硬化系数越来越大；由于切削刃刃口圆弧的存在,使得微切削的变形路径增长,相对切削长度表现出明显的尺寸效应现象；同时切削刃刃口圆弧对前下方的工件有很强的挤压作用,这也是影响微切削单位切削力的重要因素。
其次,基于切削刃刃口圆弧附近材料的单位切削力变化分析微车削加工表面完整性尺寸效应的产生机理。随着切削厚度和刃口圆弧半径比值的减小,切削刃刃口圆弧附近工件材料的单位切削力逐渐增大,材料的流动性逐渐增强,工件材料发生侧流并在刀具的前刀面和后刀面附近堆积,当前、后刀面堆积的高度与进给量达到平衡时,获得最佳的微车削表面粗糙度。微切削加工中,微刀具以较大的有效负前角挤压-剪切工件材料,已加工表面先受到前刀面的挤压,后受到后刀面的挤压。微切削中已加工表面的显微硬度随着切削厚度和刃口圆弧半径比值的减小先减小后增大,当前、后刀面作用的应力相等时,已加工表面的显微硬度值最小。
然后,分析切削厚度和切削刃刃口圆弧半径的比值对微切削毛刺高度的影响。切削刃刃口圆弧附近的工件材料在微刀具刃口圆弧挤压作用下发生侧流,形成泊松毛刺(切入毛刺和两侧毛刺)。当切削厚度小于切削刃刃口圆弧半径时,泊松毛刺的高度随着切削厚度和切削刃刃口圆弧半径的比值减小而急剧增大；当切削厚度大于切削刃刃口圆弧半径时,由于切削刃刃口圆弧附近的压力恒定不变,泊松毛刺的高度没有变化。切出毛刺是由微切削刀具推挤残留在工件边缘的切屑形成。由于单位切削力尺寸效应的影响,微切削中残留部分毛刺的高度增大。微切削的切出毛刺是一种新型卷曲毛刺,卷曲半径随着切削厚度和切削刃刃口圆弧半径的比值先减小后增大,在切削厚度和切削刃刃口圆弧半径的比值等于1时达到最小,导致切出毛刺的总高度表现出明显的尺寸效应。
最后,分析工件材料微铣削去除过程,建立包含尺寸效应的微铣削单位切削力模型,分析铣削参数(每齿进给量和轴向切削深度)、刀具参数(微铣刀直径和螺旋角角度)和铣削方式对单位切削力的影响。微铣削由于刀具螺旋角的影响使得切削方式发生转变,材料的去除机理不同于二维直角微切削。随着每齿进给量的减小,瞬时切削厚度和切削刃刃口圆弧半径的比值减小,三维单位切削力随着每齿进给量的减小而增大；随着轴向切削深度的减小,位于切入角度和切出角度区域的切削刃比例增加,三维单位切削力缓慢增大；随着微铣刀螺旋角的减小,径向和切向单位切削力逐渐增大,轴向的单位切削力逐渐减小；随着微铣刀直径的减小,三维单位切削力逐渐缓慢减小,变化趋势不明显；随着径向切削宽度的减小,径向的单位切削力逐渐增大,逆铣方式大于顺铣方式,切向的单位切削力逐渐减小,逆铣方式小于顺铣方式,轴向的单位切削力逐渐增大,两种方式差别不大。通过微铣削试验分析铣削参数、刀具参数和铣削方式对微铣削顶端毛刺的影响。由于毛刺卷曲半径的影响,顶端毛刺高度随着每齿进给量减小先减小后增大；由于参与切削的切削刃长度缩短,顶端毛刺高度随着轴向切深的减小而逐渐减小；当切削刃刃口圆弧半径和每齿进给量相等时,顶端毛刺高度最小；由于排屑能力减弱,顶端毛刺高度随着螺旋角的减小逐渐增大。
本研究得到国家自然科学基金重点项目“基于多重尺寸效应耦合的超硬微铣刀设计理论和制造技术(50935003)”和山东省自然科学杰出青年基金“超高速微细切削加工变形学研究(JQ200918)”资助。
With the development of microelectronics industry, modern medical equipment, biological engineering, national defense industry and aerospace technology, the micro parts in the range of millimeter or micron meter are demanded more complex shape, more functions, more kinds of material, higher reliability. Micro machining technology is different from etching technology, thin-film technology and LIGA technology, and it can create a complicated three-dimensional small part of different materials quickly with higher precision at lower cost, then micro cutting has a promising application prospect. Micro cutting appears some characteristics different from macro cutting such as minimum uncut chip thickness, size effect of specific cutting force and size effect of surface integrity. Investigation on the mechanism of workpiece deform is helpful to understanding the peculiar phenomenon of micro cutting process, and improve the quality of micro parts.
The extrusion effect of the cutting edge on the workpiece cannot be neglected in micro cutting and the ratio of uncut chip thickness to cutting edge radius becomes an important parameters. The deformation of workpiece is analyzed based on the slip-line field. The mechanism of size effect of specific cutting force and the effect of specific cutting force on the surface roughness and burr height are investigated. A specific milling force model of micro flat end milling is established and the factors and mechanism of top side burr in micro flat end milling experiments are analyzed.
Firstly, a deformation model is established considering the round cutting edge based on the slip-line fields. The micro orthogonal cutting forces are calculated and validated with different ratios of uncut thickness to cutting edge radius. The cutting force decreases with the ratio of uncut chip thickness to cutting edge radius decreasing, the specific cutting force increases with the decrease of uncut chip thickness to cutting edge radius. Collecting and measuring the deformed chip in micro orthogonal cutting, the deformation coefficient shows the size effect due to the pile up of the workpiece in the front of the cutting edge. With the decrease of the ratio of uncut chip thickness to cutting edge radius, the shear strain, shear strain rate, and shear temperature in the primary shear zone increases and shows the size effect phenomenon. The shear flow stress in the primary shear stress decreases due to the softening effect of the shear temperature. The plasticity strain gradient strengthening coefficient increases due to the effect of the plasticity strain gradient and the shear flow stress in the primary shear zone. The deformation path increases due to the round cutting edge and the relative cutting shows size effect phenomenon.
Secondly, the mechanism of size effect of surface integrity is investigated based on the variation of specific cutting force around the corner. Specific cutting force and the flow ability of workpiece around the comer increases when the ratio of uncut chip thickness to corner radius. The side flow takes place and the workpiece piles up in front of the cutting edge and behind the cutting edge. The best surface roughness will be got when the pile-up height of rake, flank face and feed rate reaches a balance. The cutting edge of cutting tool extrudes and shears the workpiece with the round cutting edge. The machined surface is first extruded by the rake face and then ploughed by the flank face. The micro hardness decreases first and then increases when the ratio of uncut chip thickness to cutting edge radius decreases, and it reaches the bottom when the stress around the rake face equals that of flank face.
Thirdly, the effect of specific cutting force on the burr height is studied. Side flow takes place when the tool extrudes the workpiece and the Poisson burr forms (entrance burr and side burr). The Poisson burr height increases with the decrease of the ratio of uncut chip thickness to cutting edge radius when the uncut chip thickness is smaller than the cutting edge radius. The Poisson burr height is stable because of the stable specific cutting force around the cutting edge when the uncut chip thickness is larger than the cutting edge radius. The tool extrudes the chip on the edge and the exit burr forms. The exit burr height will increase due to the effect of size effect of specific cutting force. The exit burr is a curled burr and different from that of macro cutting. The curled radius decreases first, and then increases with the decrease of the ratio of uncut chip thickness to cutting edge radius.
Finally, a specific cutting force model is established of micro flat end milling including the size effect of specific cutting force, the factors of milling parameters such as feed per tooth, axial depth of cut, tool parameters such as tool diameter, helical angle, milling method such as up milling, down milling on specific cutting force are analyzed. The milling process is different from orthogonal cutting of two dimensions due to the influence of helical angle. The specific cutting forces in the three directions increase with the decrease of the feed per tooth due the size effect of specific cutting force. The specific cutting forces in the three directions increase slowly due to the increase of cutting edge in the entrance and exit area when the axial depth of cut decreases. The specific cutting forces in the ox, oy directions increase with the decrease of the helical angle, while the specific milling force in the oz direction decrease. The specific cutting forces decrease in the three directions with the decrease of the tool diameter. The specific cutting force increases with the decrease of the radial cutting width in the ox direction, and the specific cutting force in the up milling is larger than that of down milling. The specific cutting force decreases with the decrease of the radial cutting width in the oy direction, and the specific cutting force in the up milling is smaller than that of down milling. The specific cutting force increases with the decrease of the radial cutting width in the oz direction, and the specific cutting force in the up milling is in the same level with that of down milling. The factors of milling parameters such as feed per tooth, axial depth of cut, tool parameters such as cutting edge radius, helical angle on top side burr are analyzed in micro flat end milling. The height of top side burr shows size effect with the decrease of the feed per tooth. The top side burr height decreases with the decrease of axial depth of cut due to the shortening of the cutting edge. The height of top side burr reaches the minimum when the cutting edge radius is equal to the feed per tooth. The top side burr height increases with the decrease of the helical angle due to poor clearance.
This work is sponsored by the National Natural Science Foundation of China (Grant No.50905003) and Foundation of Shandong Province of China for Distinguished Young Scholars (Grant No. JQ200918) for financial supports.
引文
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