超声振动微细铣削残余应力的研究
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摘要
随着科学技术的发展,功能、结构复杂,可靠性高的微小型产品需求不断增加,微细铣削技术作为实现产品微型化的主要技术而被广泛关注。但是,传统的微细铣削技术在加工硬脆材料等难加工材料时刀具磨损很快,加工表面质量不高,最终导致零件的使用性能达不到要求。超声振动微细铣削和传统微细铣削相比,具有能显著降低切削力、提高加工表面质量并延长刀具使用寿命的优点。其中残余应力作为表面质量的重要指标,是影响零件使用性能的主要因素,因此对超声振动微细铣削的残余应力进行研究具有重要的意义。本文针对这个问题,以降低残余应力为目标,利用有限元法对超声振动微细铣削残余应力随各影响因素的变化规律进行了系统的分析研究。
本文分析了国内外超声振动切削技术和切削加工残余应力的研究现状,并总体阐述了残余应力的产生机理、影响因素及其对零件性能的影响。
在分析前人所建立模型不足之处的基础上,使用有限元软件ABAQUS,建立了适用于超声振动微细铣削的二维有限元模型,并通过切削实验验证了模型的正确性,结合该模型对超声振动微细铣削的断屑功能和断续切削机理进行了分析。
采用所建立的二维有限元模型,对超声振动微细铣削表面残余应力进行了仿真研究,分析了工件材料、刀具几何参数、振动参数和切削用量对已加工表面残余应力的影响规律,并结合残余应力的产生机理和超声振动微细铣削的特点探讨了产生这些规律的原因。
建立并验证了超声振动微细铣削的三维有限元模型,采用该模型进行了表面残余应力的正交仿真研究,给出了各个工艺参数对残余应力影响的主次顺序,得到了残余应力的回归方程。通过三维仿真研究了超声振动微细铣削和传统微细铣削的残余应力沿已加工表面深度方向上变化规律的不同,并采用和仿真相同的工艺参数进行了槽铣实验,用X射线衍射法测定了残余应力,实验结果和仿真结果一致。
With the development of science and technology,the demand for micro products with high reliability and complicated functions and structures are continuously increas-ing, and micro-milling is extensively concerned as a main way of achieving miniaturi-zation. However, owing to the fast tool wear and low surface integrity, the parts proc-essed by conventional micro-milling (CMM) especially out of hard and brittle materi-als often cannot achieve the performance requirements. Compared to conventional mi-cro-milling, ultrasonic vibration assisted micro-milling (UVAMM) can significantly reduce the cutting force, enhance the surface integrity and extend the tool life. While as an important indicator of surface integrity, residual stress (RS) is the main factor which influences the performance of parts. Thus, it is very necessary to study the RS in UVAMM. The object of the thesis is performing a research on the influences of vari-ous factors on the RS in UVAMM in detail, and finally finds a way to reduce RS.
A summary is made to the mechanism of RS, the factors that influence RS, and the influences of RS on the performance of parts.
A 2D finite element model is especially established for UVAMM using ABAQUS. The model is verified via milling experiment. With the help of the estab-lished model, the chip-breaking function and interrupted cutting mechanism of UVAMM are analyzed.
Simulation of the surface RS in UVAMM is carried out with the previously estab-lished 2D model. The influence rules of workpiece material, tool geometric parameters, ultrasonic vibration parameters and cutting parameters on surface RS are analyzed. In-terpretations are made with the mechanism of RS and the features of UVAMM.
A 3D finite element model of UVAMM is established and verified, with which orthogonal simulation is carried out. The importance order of process parameters is obtained, and the regression equation of RS is gained. A research on the difference of RS variation with the depth from the machined surface between UVAMM and CMM is putted into practice with the established 3D model. Slot-milling experiments are im-plemented using the same process parameters as simulation, and the RS is measured with the method of X-ray diffraction. The results of simulation and experiment are in good agreement.
本文分析了国内外超声振动切削技术和切削加工残余应力的研究现状,并总体阐述了残余应力的产生机理、影响因素及其对零件性能的影响。
在分析前人所建立模型不足之处的基础上,使用有限元软件ABAQUS,建立了适用于超声振动微细铣削的二维有限元模型,并通过切削实验验证了模型的正确性,结合该模型对超声振动微细铣削的断屑功能和断续切削机理进行了分析。
采用所建立的二维有限元模型,对超声振动微细铣削表面残余应力进行了仿真研究,分析了工件材料、刀具几何参数、振动参数和切削用量对已加工表面残余应力的影响规律,并结合残余应力的产生机理和超声振动微细铣削的特点探讨了产生这些规律的原因。
建立并验证了超声振动微细铣削的三维有限元模型,采用该模型进行了表面残余应力的正交仿真研究,给出了各个工艺参数对残余应力影响的主次顺序,得到了残余应力的回归方程。通过三维仿真研究了超声振动微细铣削和传统微细铣削的残余应力沿已加工表面深度方向上变化规律的不同,并采用和仿真相同的工艺参数进行了槽铣实验,用X射线衍射法测定了残余应力,实验结果和仿真结果一致。
With the development of science and technology,the demand for micro products with high reliability and complicated functions and structures are continuously increas-ing, and micro-milling is extensively concerned as a main way of achieving miniaturi-zation. However, owing to the fast tool wear and low surface integrity, the parts proc-essed by conventional micro-milling (CMM) especially out of hard and brittle materi-als often cannot achieve the performance requirements. Compared to conventional mi-cro-milling, ultrasonic vibration assisted micro-milling (UVAMM) can significantly reduce the cutting force, enhance the surface integrity and extend the tool life. While as an important indicator of surface integrity, residual stress (RS) is the main factor which influences the performance of parts. Thus, it is very necessary to study the RS in UVAMM. The object of the thesis is performing a research on the influences of vari-ous factors on the RS in UVAMM in detail, and finally finds a way to reduce RS.
A summary is made to the mechanism of RS, the factors that influence RS, and the influences of RS on the performance of parts.
A 2D finite element model is especially established for UVAMM using ABAQUS. The model is verified via milling experiment. With the help of the estab-lished model, the chip-breaking function and interrupted cutting mechanism of UVAMM are analyzed.
Simulation of the surface RS in UVAMM is carried out with the previously estab-lished 2D model. The influence rules of workpiece material, tool geometric parameters, ultrasonic vibration parameters and cutting parameters on surface RS are analyzed. In-terpretations are made with the mechanism of RS and the features of UVAMM.
A 3D finite element model of UVAMM is established and verified, with which orthogonal simulation is carried out. The importance order of process parameters is obtained, and the regression equation of RS is gained. A research on the difference of RS variation with the depth from the machined surface between UVAMM and CMM is putted into practice with the established 3D model. Slot-milling experiments are im-plemented using the same process parameters as simulation, and the RS is measured with the method of X-ray diffraction. The results of simulation and experiment are in good agreement.
引文
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8 G.D. Kim, B.G. Loh. An Ultrasonic Elliptical Vibration Cutting Device for Micro V-groove Machining: Kinematical Analysis and Micro V-groove Machining Char-acteristics. Materials Processing Technology. 2007, (151): 221~229
9 Y. Wu, S. Yokoyama, T. Sato et al. Development of a New Ultrasonic Spindle for Precision Ultrasonically Assisted Grinding. International Journal of Machine Tools & Manufacture. 2009, (49): 933~938
10 Y. Wu, M. Nomura, M. Kato et al. Study of Internal Ultrasonic Vibration Assisted Grinding of Small Holes: Construction of Ultrasonic Vibration Spindle and Its Fundamental Performances. Abrasive Tech. 2003, 47(12): 550~555
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12 N. Kobayashi, Y. Wu, M. Nomura et al. Precision Treatment of Silicon Wafer Edge Utilizing Ultrasonically Assisted Polishing Technique. 2008, (201): 531~535
13 Z.Y. Yu, K.P. Rajurkar, A. Tandon. Study of 3D Micro-ultrasonic Machining. Jour-nal of Manufacturing Science and Engineering. 2004, (126): 727~732
14 C. Zhang, R. Rentsch, E. Brinksmeier. Advances in Micro Ultrasonic Assisted Lapping of Microstructures in Hard Brittle Materials: a Brief Review and Outlook. International Journal of Machine Tools & Manufacture. 2005, (45): 881~890
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17李勋,张德远.单激励超声椭圆振动车削薄壁筒实验研究.航空学报. 2006,27(4): 720~723
18马春翔,社本英二,森肋俊道.超声波椭圆振动切削提高加工系统稳定性的研究.兵工学报. 2004, 25(6): 752~756
19 C.X. Ma, E. Shamoto, T. Moriwak et al. Suppression of Burrs in Turning with Ul-trasonic Elliptical Vibration Cutting. International Journal of Machine Tools & Manufacture. 2005, (45): 1295~1300
20杨亮.塑性材料超声振动精密切削技术的研究.哈尔滨工业大学博士学位论文. 2007
21 G.L. Chern, Y.C. Chang. Using Two-dimensional Vibration Cutting for Micro-milling. International Journal of Machine Tools & Manufacture. 2006, (46): 659~666
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32 E. Capello. Residual Stresses in Turning Part II: Influence of the Machined Mate-rial. Journal of Material Processing Technology. 2006, (172): 319~326
33 M. Mohammadpour, M.R. Razfar, R. Jalili Saffar. Numerical Investigating the Ef-fect of Machining Parameters on Residual Stresses in Orthogonal Cutting. Simula-tion Modelling Practice and Theory. 2010, (18): 378-389
34 M.N.A. Nasr, E.G. Ng, M.A. Elbestawi. A Modified Time-efficient FE Approach for Predicting Maching-induced Residual Stresses. Finite Elements in Analysis and Design. 2008, (44): 149~161
35 D. Umbrello, G. Ambrogio, L. Filice et al. A Hybrid Finite Element Method-artificial Neural Network Approach for Predicting Residual Stresses and the Opti-mal Cutting Conditions during Hard Turning of AISI 52100 Bearing Steel. Materi-als and Design. 2008, (29): 873~883
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37王秋成.航空铝合金残余应力消除及评估技术研究.浙江大学博士学位论文. 2003
38黄志刚.航空整体结构件铣削加工变形的有限元模拟理论及方法研究.浙江大学博士学位论文. 2003
39王树宏.航空铝合金厚板初始残余应力及其对铣削变形影响的基础研究.南京航空航天大学博士学位论文. 2005
40郭魂.航空多框整体结构件铣削变形机理与预测分析研究.南京航空航天大学博士学位论文. 2005
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2张定诠,何家文.材料中残余应力的X射线衍射分析和作用.西安交通大学出版社, 1999
3顾立志,龙泽明,冉启文等.振动切削研究状况及发展趋势.佳木斯大学学报(自然科学版). 2000, 18(2): 120~125
4 V.I. Babitsky, A.N. Kalashnikov, F.V. Molodtsov. Autoresonant Control of Ultra-sonically Assisted Cutting. Mechatronics. 2004, (14): 91~114
5 V.I. Babitsky, A.V. Mitrofanov, V.V. Silberschmidt. Ultrasonically Assisted Turn-ing of Aviation Materials: Simulations and Experimental Study. Ultrasonics. 2004, (42): 81~86
6 V.I. Babitsky, A.N. Kalashnikov, A.Meadows et al. Ultrasonically Assisted Turning of Aviation Materials. Materials Processing Technology. 2003, (132): 157~167
7 J. Pujana, A. Rivero, A. Celaya et al. Analysis of Ultrasonic-assisted Drilling of Ti6Al4V. International Journal of Machine Tools & Manufacture. 2009, (49): 500~508
8 G.D. Kim, B.G. Loh. An Ultrasonic Elliptical Vibration Cutting Device for Micro V-groove Machining: Kinematical Analysis and Micro V-groove Machining Char-acteristics. Materials Processing Technology. 2007, (151): 221~229
9 Y. Wu, S. Yokoyama, T. Sato et al. Development of a New Ultrasonic Spindle for Precision Ultrasonically Assisted Grinding. International Journal of Machine Tools & Manufacture. 2009, (49): 933~938
10 Y. Wu, M. Nomura, M. Kato et al. Study of Internal Ultrasonic Vibration Assisted Grinding of Small Holes: Construction of Ultrasonic Vibration Spindle and Its Fundamental Performances. Abrasive Tech. 2003, 47(12): 550~555
11 M. Nomura, Y. Wu, M. Kato et al. Study of Internal Ultrasonic Vibration Assisted Grinding of Small Holes: Mechanism of Grinding Force Reduction Due to Ultra-sonic Vibration. Abrasive Tech. 2005, 49(12): 691~696
12 N. Kobayashi, Y. Wu, M. Nomura et al. Precision Treatment of Silicon Wafer Edge Utilizing Ultrasonically Assisted Polishing Technique. 2008, (201): 531~535
13 Z.Y. Yu, K.P. Rajurkar, A. Tandon. Study of 3D Micro-ultrasonic Machining. Jour-nal of Manufacturing Science and Engineering. 2004, (126): 727~732
14 C. Zhang, R. Rentsch, E. Brinksmeier. Advances in Micro Ultrasonic Assisted Lapping of Microstructures in Hard Brittle Materials: a Brief Review and Outlook. International Journal of Machine Tools & Manufacture. 2005, (45): 881~890
15李祥林,薛万夫,张日升.振动切削及其在机械加工中的应用.科学技术出版社, 1985
16季远,李勋,张德远.超声椭圆振动精密切削.航空制造技术. 2005, (4): 92-95
17李勋,张德远.单激励超声椭圆振动车削薄壁筒实验研究.航空学报. 2006,27(4): 720~723
18马春翔,社本英二,森肋俊道.超声波椭圆振动切削提高加工系统稳定性的研究.兵工学报. 2004, 25(6): 752~756
19 C.X. Ma, E. Shamoto, T. Moriwak et al. Suppression of Burrs in Turning with Ul-trasonic Elliptical Vibration Cutting. International Journal of Machine Tools & Manufacture. 2005, (45): 1295~1300
20杨亮.塑性材料超声振动精密切削技术的研究.哈尔滨工业大学博士学位论文. 2007
21 G.L. Chern, Y.C. Chang. Using Two-dimensional Vibration Cutting for Micro-milling. International Journal of Machine Tools & Manufacture. 2006, (46): 659~666
22 G.L. Chern, H.J. Lee. Using Workpiece Vibration Cutting for micro-drilling. Int J Adv Manuf Technol. 2006, (27): 688~692
23 X.X. Yu, W.S. Lau, T.C. Lee. A Finite Element Analysis of Residual Stresses in Stretch Turning. Int. J. Mach. Tools Manufact. 1997, 37(10): 1525~1537
24 C. Shet, X. Deng. Residual Stresses and Strains in Orthogonal Metal Cutting. In-ternational Journal of Machine Tools & Manufacture. 2003, (43): 573~587
25 E.K. Henriksen. Residual Stresses in Machined Surfaces. American Society of Mechanical Engineers——Transactions. 1951, 73(1): 69~76
26 E. Capello. Residual Stresses in Turning Part I: Influence of Process Parameters. Journal of Material Processing Technology. 2006, (172): 319~326
27 H. Sasahara. The Effect on Fatigue Life of Residual Stress and Surface Hardness Resulting from Different Cutting Conditions of 0.45%C steel. International Journal of Machine Tools & Manufacture. 2005, (45): 131~136
28 T. Segawa, H. Sasahara, M. Tsutsumi. Development of a New Tool to Generate Compressive Residual Stress within a Machined Surface. International Journal of Machine Tools & Manufacture. 2004, 44(11): 1215~1221
29 H. Sasahara, T. Obikawa, T. Shirakashi. Prediction Model of Surface Residual Stress within a Machined Surface by Combining two Orthogonal Plane Models. International Journal of Machine Tools & Manufacture. 2004, 44(7~8): 815~822
30 J. Sun, Y.B. Guo. A Comprehensive Experimental Study on Surface Integrity by End Milling Ti-6Al-4V. Journal of Materials Processing Technology. 2009, (209): 4036~4042
31 Y.B. Guo, A.W. Warren, F. Hashimoto. The Basic Relationships between Residual Stress, White Layer, and Fatigue Life of Hard Turned and Ground in Rolling Con-tact. CIRP Journal of Manufacturing Science and Technology. 2010, (65): 6
32 E. Capello. Residual Stresses in Turning Part II: Influence of the Machined Mate-rial. Journal of Material Processing Technology. 2006, (172): 319~326
33 M. Mohammadpour, M.R. Razfar, R. Jalili Saffar. Numerical Investigating the Ef-fect of Machining Parameters on Residual Stresses in Orthogonal Cutting. Simula-tion Modelling Practice and Theory. 2010, (18): 378-389
34 M.N.A. Nasr, E.G. Ng, M.A. Elbestawi. A Modified Time-efficient FE Approach for Predicting Maching-induced Residual Stresses. Finite Elements in Analysis and Design. 2008, (44): 149~161
35 D. Umbrello, G. Ambrogio, L. Filice et al. A Hybrid Finite Element Method-artificial Neural Network Approach for Predicting Residual Stresses and the Opti-mal Cutting Conditions during Hard Turning of AISI 52100 Bearing Steel. Materi-als and Design. 2008, (29): 873~883
36王立涛.关于航空框类结构件铣削加工残余应力和变形机理的研究.浙江大学博士学位论文. 2003
37王秋成.航空铝合金残余应力消除及评估技术研究.浙江大学博士学位论文. 2003
38黄志刚.航空整体结构件铣削加工变形的有限元模拟理论及方法研究.浙江大学博士学位论文. 2003
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