超声铣削SiCp/Al复合材料的机理研究
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摘要
碳化硅颗粒增强铝基复合材料复合材料(简称SiCp/Al复合材料)是一种新型复合材料,以其卓越的性能受到了世界各国的重视。但由于其内部具有较高硬度的增强相,使得其机械加工变得非常困难,现已成为阻碍其工业应用的瓶颈。为了解决SiCp/Al复合材料的难加工问题,本文将超声波振动加工引入普通铣削中,以期在保证优良表面质量的同时降低铣削温度,减少刀具磨损。
本文以研究超声波铣削加工工艺为目的,设计了铣削SiCp/Al复合材料超声波振动加工系统和半人工热电偶测温装置,并利用Labview程序平台设计了测温程序;建立了超声振动切削温度场的传热模型和超声振动切削力的理论模型,并通过实验对理论模型进行了验证;利用自制的超声波铣削系统对加工过程中的切削温度的变化规律、切削力的变化规律状况进行了试验研究;最后通过工具显微镜,分析了SiCp的变形破坏方式、工件表面的微观结构和切削过程中的刀具磨损状态。
结果表明:在相同切削参数下,超声铣削SiCp/Al复合材料时的切削温度要比普通铣削时低20～30°C,切削力要低30～40N;在铣削SiCp/Al复合材料时,刀具磨损主要是前刀面的颗粒磨损和后刀面的挤压磨损;利用超声波振动铣削可以提高工件表面质量,降低刀具磨损。
SiC particle reinforced aluminum matrix composites (abbreviated SiCp/Al composites) is a new type of composite material, with its superior performance has been of great importance to all countries in the world. But the machining is very difficult due to the rigidity of its internal reinforced-phase, and it has become the bottleneck which restricts its industry application. In order to settle the difficult machining problem of SiCp/Al composites, ultrasonic vibration machining is introduced to common cutting in this thesis for the purpose of obtaining the fine surface quality as well as reducing cutting temperature and decrease tool wear.
This paper focuses on studying the ultrasonic milling process for the purpose. The ultrasonic vibration milling device and semi-artificial thermocouple temperature measurement devices are developed. The procedure of the temperature measurement is designed by using Labview procedure. The heat diffusion model of ultrasonic cutting temperature field and Model of Ultrasonic Vibration Cutting are established, and the models of theoretical verified by experiments; Through the experiment the change law of the cutting force and cutting temperature are studied; Finally, the distortion damage mode of SiCp, Microstructure on surface of workpiece and the status of tool wear during the cutting are analyzed by Scanning Tool Microscope.
The results of the experiment show that, in the same cutting parameters, the cutting temperature with the ultrasonic vibration cutting of SiCp/Al composites is lower 20～30oC than the ordinary cutting, and cutting force lower 30～40N; Tool wear in ultrasonic vibration cutting of SiCp/Al composites are mainly particle attrition of rake face and rear face of extrusion attrition; ultrasonic vibration cutting can decrease the tool wear and improve the quality of processing surface.
本文以研究超声波铣削加工工艺为目的,设计了铣削SiCp/Al复合材料超声波振动加工系统和半人工热电偶测温装置,并利用Labview程序平台设计了测温程序;建立了超声振动切削温度场的传热模型和超声振动切削力的理论模型,并通过实验对理论模型进行了验证;利用自制的超声波铣削系统对加工过程中的切削温度的变化规律、切削力的变化规律状况进行了试验研究;最后通过工具显微镜,分析了SiCp的变形破坏方式、工件表面的微观结构和切削过程中的刀具磨损状态。
结果表明:在相同切削参数下,超声铣削SiCp/Al复合材料时的切削温度要比普通铣削时低20～30°C,切削力要低30～40N;在铣削SiCp/Al复合材料时,刀具磨损主要是前刀面的颗粒磨损和后刀面的挤压磨损;利用超声波振动铣削可以提高工件表面质量,降低刀具磨损。
SiC particle reinforced aluminum matrix composites (abbreviated SiCp/Al composites) is a new type of composite material, with its superior performance has been of great importance to all countries in the world. But the machining is very difficult due to the rigidity of its internal reinforced-phase, and it has become the bottleneck which restricts its industry application. In order to settle the difficult machining problem of SiCp/Al composites, ultrasonic vibration machining is introduced to common cutting in this thesis for the purpose of obtaining the fine surface quality as well as reducing cutting temperature and decrease tool wear.
This paper focuses on studying the ultrasonic milling process for the purpose. The ultrasonic vibration milling device and semi-artificial thermocouple temperature measurement devices are developed. The procedure of the temperature measurement is designed by using Labview procedure. The heat diffusion model of ultrasonic cutting temperature field and Model of Ultrasonic Vibration Cutting are established, and the models of theoretical verified by experiments; Through the experiment the change law of the cutting force and cutting temperature are studied; Finally, the distortion damage mode of SiCp, Microstructure on surface of workpiece and the status of tool wear during the cutting are analyzed by Scanning Tool Microscope.
The results of the experiment show that, in the same cutting parameters, the cutting temperature with the ultrasonic vibration cutting of SiCp/Al composites is lower 20～30oC than the ordinary cutting, and cutting force lower 30～40N; Tool wear in ultrasonic vibration cutting of SiCp/Al composites are mainly particle attrition of rake face and rear face of extrusion attrition; ultrasonic vibration cutting can decrease the tool wear and improve the quality of processing surface.
引文
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[2]樊建中等.颗粒增强铝基复合材料的研制应用与发展[J].材料导报,2001.15(10)
[3] Aude Hauert, Andreas Rossoll, Andreas Mortensen.Ductile-to-brittle transition in tensile failure of particle-reinforced metals[J].Journal of the Mechanics and Physics of Solids, Volume 57, Issue 3,March 2009. Pages 473-499
[4]于琨.金属基复合材料研究的当前形势与面临的问题[J].高技术通讯,1993.(5):11-14
[5]王大镇.颗粒增强铝复合材料切削力特性研究[J].机械工程师,2005.3:17-19
[6]于春田.金属基复合材料[M].北京:冶金工业出版社,1995
[7] R.I. Robert. Metal matrix composites pose a big challenge to conventional alloys, Space Shuttle, 1985
[8]赵渠森.先进复合材料及其应用[J].航空制造技术,2002.10:22-27
[9] F.H.Force. Aerospace Materials for the Twenty - First Centure[J]. Mater& Dedign, 1989.10(3):110-119
[10] GE.D'Errico. Turning of metal matrix composites[J]. Journal of Materials Procesing Tchnology,2001.(119):257-260
[11] J Paulo Davim et al.Optimal drilling of particulate metal matrix composites based on experimental and numerical procedures[J]. International Journal of Machine Tools & Manufacture,2001.41:23-31
[12]全燕鸣,于启勋等.铝基SiC颗粒加强复合材料的切削加工研究[J].工具技术,2000.增刊:16-18
[13] F Muller et al. Non-conventional Machining of Particle Reinforced Metal Matrix Composites[J].Materials Processing Technology, 1996.11(1):17-29
[14] C.F.Cheung.Efect of reinforcement in ultra-precision machining of A16061/Sicmetal matrix composites[J]. Sc riptam aterialia,2002.(47):77-82
[15] X.P.Li. Tool wear acceleration interrelation on workpiece reinforcement Percent agein cutting of metal matrix composite[J]. Manchester,2001.(247):161-171
[16]姚洪权.SiCp/2024复合材料切削性能研究[D].哈尔滨:哈尔滨工业大学,1996
[17] M.EI-Gallab,M.Sklad.Machining of Al/SiC Particulate Metal Matrix Composites[J]. Workpiece Surface Integrity.J.Mater.Process,1998.83(3): 227-285
[18] GRutelli, S.Durante.Aluminum-based MMc machining with diamond-coatedcutting tools[J]. Surfaceand CoatingsT echnology,1997.(94):632-640
[19]全燕鸣.硬脆颗粒增强铝基复合材料的切削区变形[J].华南理工大学学报,1998.26 (4):27-29
[20] T.B.THOE,D.K.ASPINWALL,M.L.H.WISE.REVIEW ON ULTEASONIC MACHINING[J]. Mchine Tools & Manufscture,VOL. 1998.(38):239-255
[21]隈部淳一朗.精密加工振动切削(基础与应用)[M].机械工业出版社,1985
[22]张云电.超声加工及其应用[M].北京:国防工业出版社,1995
[23]张勤俭.超声加工技术的研究现状及其发展趋势[J].电加工与模具,2005
[24]曹风国.超声加工技术[M].北京:化学工业出版社,2004
[25] H.Hocheng, N.H.Tai, C.S.Liu. Assessment of ultrasonic drilling of C/SiC composite material [J]. Composites: Part A 2000. 31:133-142
[26] Qixin Zhang.Study on ultrasonic vibration drilling in carbon fiber reinforced polymers[J]. Chinese Journal of Mechanical Engineering (English Edition), 1994.7(1):72-77
[27] J.D.Kim,E.S.Lee. A study of the ultrasonic-vibration cutting of carbonfiber reinforced plastics[J]. J. Mater. Process. Technol,1994.43(2):259-277
[28]焦锋,赵波,刘传绍.金属基复合材料SiCp/Al的振动切削特性研究[J].焦作工学院学报(自然科学版),2002.21(4):275-278
[29]焦锋,赵波,刘传绍等. PCD刀具超声振动车削SiCp/Al复合材料时的切削力特性研究[J].工具技术,2002.36(8):22-25
[30]铁占续,赵波.金属基复合材料超声切削特性的研究[J].制造技术与机床,2003.4:36-37
[31]徐可伟,朱训生,赵波等.颗粒增强铝基复合材料的振动切削研究[J].航天工艺,2001.3:1-6
[32]夏靖宇,朱训生,徐可伟等.超声振动切削金属基复合材料的刀具磨损[J].航空精密制造技术,2002.38(2)
[33]周泽华.金属切削理论[M].北京:机械工业出版社,1987
[34]张幼桢.金属切削理论[M].北京:机械工业出版社,1988
[35] J. T. Lin et al. Chip formation in the machining of SiC-Particle-Reinforced Aluminium-Matrix Composites[J]. Composites Science and Technology, 1998 285-291.
[36]徐可伟.薄壁零件超声振动切削工艺及其声学系统理论研究[D].上海:上海交通大学,2001
[37] G. Arnold, L. Leiteritz, S. Zahn,H. Rohm. Ultrasonic cutting of cheese: Composition affects cutting work reduction and energy demandInternational Dairy Journal, Volume 19, Issue 5, 2009. 314-320
[38]林仲茂.超声变幅杆的原理和设计[M].北京:科学出版社,1987
[39]袁易全.超声换能器[M].南京:南京大学出版社,1992
[40]舒畅.高速铣削钛合金的切削温度研究[D].南京:南京航空航天大学,2005
[41]侯镇冰,何绍杰,李恕先编著.固体热传导[M].上海:上海科学技术出版社出版,1984
[42]徐鸿钧,徐西鹏,张幼桢等.断续磨削时工件表面温度场解析[J].机械工程学报,1994.30(1):30-36
[43]颜竟成,石世宏,王剑彬.超声振动车削试验与理论分析[J].衡阳工学院学报,1990.4(1):61-66
[44] Fan Rui,Li Zhiqiang,Chen Wuyi. An experimental research on drilling temperature of carbon fiber reinforced plastic[J]. Progress of Machining Technology,Beijing:Aviation Industry Press, 2002
[45]袁哲俊.金属切削实验技术[M].北京:机械工业出版社,1988
[46]吴震宇.难加工材料高速铣削动态参数测试及机理研究[D].上海:上海交通大学,2004
[47]万在红,彭春华.切削温度测量的虚拟仪器[J].南昌航空工业学院学报(自然科学版),2003.17(3):77-80
[48]臼井英治,白铿高洋.金属加工力学[M].北京:国防工业出版社,1984
[49]陈日曜.金属切削原理(第二版)[M].北京:机械工业出版社,2002:99-100
[50] YAltinas,et al. Predietion of Cutting Force and Tool Breakage in Milling from Feed Drive CurrentMeasurements[J]. Trans.ASME.J.of Engineering for lndustry,1992,114(8):386
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