KFRP复合材料螺旋铣削工艺制孔质量
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摘要
文摘凯夫拉纤维增强复合材料(KFRP)在钻削过程中会产生严重的分层、起毛等缺陷,难以满足装配工序的要求。本文将螺旋铣削工艺运用于KFRP复合材料制孔,进行了偏心距、主轴转速和刀具类型的单因素试验,以分层因子、起毛面积和孔径偏差表征KFRP复合材料螺旋铣削的制孔质量,深入研究不同工况下的缺陷抑制机理和制孔质量。结果表明,偏心距、主轴转速和刀具结构对制孔质量均有显著影响,采用波形四刃铣刀在偏心距0.5 mm和主轴转速4 000 r/min工况下的制孔质量最好,分层因子和孔径偏差分别为1.27和1.2%,起毛面积比二刃铣刀下降了13.7%。
Delamination and fuzzing defects during drilling of KFRP composites are too severe to meet the requirements in assembling process. Therefore,orbital drilling is proposed to drill KFRP composites in this study. Single factor experiments are conducted to investigate the hole quality and inhabitation mechanisms in different working conditions. Delamination factor,fuzzing area and diameter deviation are presented to characterize the hole quality. The experimental results indicate that there are close influences of eccentricity,spindle speed and cutter geometry on hole quality. When four-flute end mill with waved edges is used,hole quality is the best in working condition of e = 0.5 mm and N = 4 000 r/min. The delamination factor and diameter deviation are 1.27 and 1.2% respectively,and reduction of fuzzing area from drilling with two-flute end mill is 13.7%.
Delamination and fuzzing defects during drilling of KFRP composites are too severe to meet the requirements in assembling process. Therefore,orbital drilling is proposed to drill KFRP composites in this study. Single factor experiments are conducted to investigate the hole quality and inhabitation mechanisms in different working conditions. Delamination factor,fuzzing area and diameter deviation are presented to characterize the hole quality. The experimental results indicate that there are close influences of eccentricity,spindle speed and cutter geometry on hole quality. When four-flute end mill with waved edges is used,hole quality is the best in working condition of e = 0.5 mm and N = 4 000 r/min. The delamination factor and diameter deviation are 1.27 and 1.2% respectively,and reduction of fuzzing area from drilling with two-flute end mill is 13.7%.
引文
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[2]YILBAS B S,AKHTARS S.Laser cutting of Kevlar laminates and thermal stress formed at cutting sections[J].Optics&Lasers in Engineering,2012,50(2):204-209.
[3]KHASHABA U A,EL-KERAN A A.Drilling analysis of thin woven glass-fiber reinforced epoxy composites[J].Journal of Materials Processing Technology,2017,249:415–425.
[4]郭丽.高性能轻质装甲材料加工技术的研究[D].南京理工大学,2006.
[5]石文天,刘汉良,张加波,等.芳纶纤维复合材料切削加工缺陷研究[J].中国塑料,2013,27(4):71-74.
[6]PERSSON E,ERIKSSON I,ZACKRISSON L.Effects of hole machining defects on strength and fatigue life of composite laminates[J].Composites Part A,Applied Science&Manufacturing,1997,28(2):141-151.
[7]庄原.芳纶纤维复合材料切磨复合加工技术研究[D].大连理工大学,2013.
[8]刘汉良,张加波,王震,等.碳纤维与芳纶纤维复合材料机械加工刀具选用[J].宇航材料工艺,2013,43(4):95-98.
[9]DURO L M P,GONALVES D J S,TAVARES J M R S,et al.Drilling tool geometry evaluation for reinforced composite laminates[J].Composite Structures,2010,92(7):1545-1550.
[10]HOCHENG H,TSAO C C.Effects of special drill bits on drilling-induced delamination of composite materials[J].International Journal of Machine Tools&Manufacture,2006,46(12/13):1403-1416.
[11]DENKENA B,BOEHNKE D,DEGE J H.Helical milling of CFRP-titanium layer compounds[J].Cirp Journal of Manufacturing Science&Technology,2008,1(2):64-69.
[12]LIU C,WANG G,DARGUSCH M S.Modeling,simulation and experimental investigation of cutting forces during helical milling operations[J].International Journal of Advanced Manufacturing Technology,2012,63(9-12):839-850.
[13]王海艳.难加工材料螺旋铣孔动力学研究[D].天津大学,2012.
[14]王奔,高航,毕铭智,等.C/E复合材料螺旋铣削制孔方法抑制缺陷产生的机理[J].机械工程学报,2012,48(15):173-181.
[15]刘刚,张恒,王亚飞,等.碳纤维增强复合材料螺旋铣孔切削力及加工质量研究[J].复合材料学报,2014,31(5):1292-1299.
[16]张硕,胡永祥,姚振强.碳纤维复合材料螺旋铣孔出口缺陷试验研究[J].组合机床与自动化加工技术,2014,(6):8-11.
[17]BRINKSMEIER E,FANGMANN S,RENTSCH R.Drilling of composites and resulting surface integrity[J].CIRP Annals-Manufacturing Technology,2011,60(1):57-60.
[18]WAN Y Z,CHEN G C,HUANGY,et al.Characterization of three-dimensional braided carbon/Kevlar hybrid composites for orthopedic usage[J].Materials Science&Engineering A,2005,398(1/2):227-232.
[19]秦旭达,陈仕茂,刘伟成,等.螺旋铣孔技术在航空制造装配业中的发展应用[J].航空制造技术,2009,(6):58-60.
[20]靳晓丽.轻质特种防护材料加工技术的研究[D].南京理工大学,2004.