微径钻铣刀具的失效形式及抑制措施分析
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摘要
由于具有刃口半径效应、径向刚度差、旋转速度高、切削稳定性差等特性,微径钻、铣刀具具有不同于常规尺度钻、铣刀具的失效特征。基于大量钻削和立铣削试验,在对常规尺度麻花钻、平头立铣刀的一般失效形式简要分析的基础上,研究了微径麻花钻和平头立铣刀的特殊失效形式及原因,提出了抑制微径钻、铣刀具失效的基本方法。结果表明:容屑空间堵塞、塑性变形、断齿是微径钻、铣刀具常见的失效形式;随着刀具直径减小、转速增高,整体断裂成为微径钻、铣刀具的最主要失效形式;改善材料切削性能、提高切削液作用效果、优选刀具材料及结构、优化切削工艺是抑制微径钻、铣刀具失效的根本措施。
Because of size effect,weak radial stiffness,high rotational speed and low machining stability,micro drilling and end milling operations have different mechanism of tool failure from macro drilling and milling operations. Based on plenty of experiments of micro-drilling and micro-end-milling,the special failure modes of micro twist drill and end mill were studied and the methods of controlling tool failure were put forward. The result shows that,the congestion of chip space,plastic deformation and tool teeth breakage are usual failure modes of micro diameter drilling and milling tool;the whole fracture becomes the leading failure mode of micro drilling and milling tool with the decrease of tool diameter and the increase of spindle speed;the basic methods of suppressing the tool failure have mainly changing cutting performance of workpiece material,improving action effect of cutting fluid,choosing appropriate tool material and structure,and optimizing machining process.
Because of size effect,weak radial stiffness,high rotational speed and low machining stability,micro drilling and end milling operations have different mechanism of tool failure from macro drilling and milling operations. Based on plenty of experiments of micro-drilling and micro-end-milling,the special failure modes of micro twist drill and end mill were studied and the methods of controlling tool failure were put forward. The result shows that,the congestion of chip space,plastic deformation and tool teeth breakage are usual failure modes of micro diameter drilling and milling tool;the whole fracture becomes the leading failure mode of micro drilling and milling tool with the decrease of tool diameter and the increase of spindle speed;the basic methods of suppressing the tool failure have mainly changing cutting performance of workpiece material,improving action effect of cutting fluid,choosing appropriate tool material and structure,and optimizing machining process.
引文
[1]Denkena B,Hoffmeister H-w.,Reichstein M.Micro-machining processes for microsystem technology[J].Microsystem Technology,2006(12):659-664.
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[4]Guo An-ping.Investigation of the static and dynamic characteristic of micro-drilling[D].University of Arkansas,2004.
[5]Srinivasa Y.-v,Shunmuga M.-s.Mechanistic model for prediction of cutting forces in micro end-milling and experimental comparison[J].International Journal of Machine Tools&Manufacture,2013(67):18-27.
[6]Wang J,Liu Y-B,An J.Wear mechanism map of uncoated HSS tools during drilling die-cast magnesium alloy[J].Wear,2008(265):685-691.
[7]Imran Muhammad,Mativeng Paul-T,Gholinia Ali.Comparison of tool wear mechanisms and surface integrity for dry and wet micro-drilling of nickelbase superalloys[J].International Journal of Machine Tools&Manufacture,2014(76):49-60.
[8]Kudla L-A.Deformations and strength of miniature drills[J].Journal of Engineering Manufacture,2006(220):389-396.
[9]马利杰,刘贯军,王贵成.轴向振动钻削的断屑机理研究[J].机械设计与制造,2009(2):228-230.(Ma Li-jie,Liu Guan-jun,Wang Gui-cheng.Study on mechanism of breaking chip of Axial vibration drilling[J].Machinery Design&Manufacture,2009(2):228-230.)
[10]Ding Hong-tao,Shen Ning-gang,Shin Y-c.Thermal and mechanical modeling analysis of laser-assisted micro-milling of difficult-to-machine alloys[J].Journal of Materials Processing Technology,2012(212):601-613.
[2]Dornfeld D,Min S,Takeuchi Y.Recent advances in mechanical micromachining[J].Annals of CIRP,2006,55(2):745-768.
[3]王先逵.广义制造论[J].机械工程学报,2003,39(10):86-94.(Wang Xian-kui.Broad manufacturing theory[J].Chinese Journal of Mechanical Engineering,2003,39(10):86-94.)
[4]Guo An-ping.Investigation of the static and dynamic characteristic of micro-drilling[D].University of Arkansas,2004.
[5]Srinivasa Y.-v,Shunmuga M.-s.Mechanistic model for prediction of cutting forces in micro end-milling and experimental comparison[J].International Journal of Machine Tools&Manufacture,2013(67):18-27.
[6]Wang J,Liu Y-B,An J.Wear mechanism map of uncoated HSS tools during drilling die-cast magnesium alloy[J].Wear,2008(265):685-691.
[7]Imran Muhammad,Mativeng Paul-T,Gholinia Ali.Comparison of tool wear mechanisms and surface integrity for dry and wet micro-drilling of nickelbase superalloys[J].International Journal of Machine Tools&Manufacture,2014(76):49-60.
[8]Kudla L-A.Deformations and strength of miniature drills[J].Journal of Engineering Manufacture,2006(220):389-396.
[9]马利杰,刘贯军,王贵成.轴向振动钻削的断屑机理研究[J].机械设计与制造,2009(2):228-230.(Ma Li-jie,Liu Guan-jun,Wang Gui-cheng.Study on mechanism of breaking chip of Axial vibration drilling[J].Machinery Design&Manufacture,2009(2):228-230.)
[10]Ding Hong-tao,Shen Ning-gang,Shin Y-c.Thermal and mechanical modeling analysis of laser-assisted micro-milling of difficult-to-machine alloys[J].Journal of Materials Processing Technology,2012(212):601-613.