碳纤维复合材料超声振动铣削的技术基础研究
|
摘要
碳纤维增强复合材料(CFRP)具有比强度和比刚度高、抗疲劳性能好、耐热性优良等优点,己广泛用于航天、航空、汽车、体育娱乐及其他领域,是应用最广泛的一种先进复合材料。但由于其内部具有较高硬度的增强相而使得其机械加工性变得非常困难,加工刀具磨损严重,零件表面质量差,加工效率低。因此,碳纤维增强复合材料的精密加工,已成为目前复合材料研究和应用所面临的一项亟待解决的难题。
为了解决碳纤维复合材料的难加工问题,本文将超声振动引入普通切削中,以期在保证优良表面质量的同时降低切削力和切削温度、减少刀具磨损。研制了超声振动铣削装置,并进行了振动特性试验;通过理论推导,建立了超声振动铣削碳纤维复合材料的平均切削力理论模型和切削温度场的传热学模型;通过碳纤维复合材料的普通切削和超声振动切削试验,研究了不同切削参数对切削力、切削温度、刀具磨损及表面粗糙度的影响规律;分析了碳纤维复合材料的超声振动切削机理,得出了在超声振动切削条件下,切削力和切削温度低、刀具磨损量小、工件表面质量好的结论;通过对工件表面的微观结构的分析,指出了碳纤维复合材料在加工过程中的主要缺陷;讨论分析了刀具的失效形式和刀具的磨损机理,指出超声振动铣削条件下,能减小刀具磨损,提高工件表面质量。
Carbon fiber reinforced plastics(CFRP) are characterized by superior strength-to-weight and stiffness-to-weight ratios, high fatigue strength and good heat resistance.They have been used widely in airplanes, spaceships, automobiles and sport equipment, etc. But the machining is very difficult due to the rigidity of its internal reinforced-phase, the tool wear is very severity, the quality of surface is very bad and the machining efficiency is low. So the precision machining of CFRP has became a puzzle waiting for solving in functional reinforced composites’investagation and applications now.
In order to settle the difficult machining problem of CFRP, ultrasonic vibration is introduced to common cutting in this thesis for the purpose of obtaining the fine surface quality as well as reducing cutting temperature and cutting force、decreasing the tool wear. The ultrasonic vibration cutting device is developed and the vibration characteristics of ultrasonic vibration turning acoustic system is researched. Through theoretical derivation,the average cutting force model and the heat diffusion model of ultrasonic cutting temperature field are established. Through the experiment of common cutting and ultrasonic vibration cutting CFRP, the influence of different parameters on cutting temperature, cutting force, the tool wear and surface roughness are studied. The ultrasonic vibration cutting mechanics of CFRP is analyzed, ultrasonic cutting has lower cutting temperature and cutting force, smaller tool wear and finer surface quality than common cutting. Through the surface of the micro-structure analysis, pointing out the main defects in machining CFRP.The wear-out mechanism of tool is dicussed,there are better surface quality and smaller tool wear in ultrasonic cutting.
为了解决碳纤维复合材料的难加工问题,本文将超声振动引入普通切削中,以期在保证优良表面质量的同时降低切削力和切削温度、减少刀具磨损。研制了超声振动铣削装置,并进行了振动特性试验;通过理论推导,建立了超声振动铣削碳纤维复合材料的平均切削力理论模型和切削温度场的传热学模型;通过碳纤维复合材料的普通切削和超声振动切削试验,研究了不同切削参数对切削力、切削温度、刀具磨损及表面粗糙度的影响规律;分析了碳纤维复合材料的超声振动切削机理,得出了在超声振动切削条件下,切削力和切削温度低、刀具磨损量小、工件表面质量好的结论;通过对工件表面的微观结构的分析,指出了碳纤维复合材料在加工过程中的主要缺陷;讨论分析了刀具的失效形式和刀具的磨损机理,指出超声振动铣削条件下,能减小刀具磨损,提高工件表面质量。
Carbon fiber reinforced plastics(CFRP) are characterized by superior strength-to-weight and stiffness-to-weight ratios, high fatigue strength and good heat resistance.They have been used widely in airplanes, spaceships, automobiles and sport equipment, etc. But the machining is very difficult due to the rigidity of its internal reinforced-phase, the tool wear is very severity, the quality of surface is very bad and the machining efficiency is low. So the precision machining of CFRP has became a puzzle waiting for solving in functional reinforced composites’investagation and applications now.
In order to settle the difficult machining problem of CFRP, ultrasonic vibration is introduced to common cutting in this thesis for the purpose of obtaining the fine surface quality as well as reducing cutting temperature and cutting force、decreasing the tool wear. The ultrasonic vibration cutting device is developed and the vibration characteristics of ultrasonic vibration turning acoustic system is researched. Through theoretical derivation,the average cutting force model and the heat diffusion model of ultrasonic cutting temperature field are established. Through the experiment of common cutting and ultrasonic vibration cutting CFRP, the influence of different parameters on cutting temperature, cutting force, the tool wear and surface roughness are studied. The ultrasonic vibration cutting mechanics of CFRP is analyzed, ultrasonic cutting has lower cutting temperature and cutting force, smaller tool wear and finer surface quality than common cutting. Through the surface of the micro-structure analysis, pointing out the main defects in machining CFRP.The wear-out mechanism of tool is dicussed,there are better surface quality and smaller tool wear in ultrasonic cutting.
引文
[1]赵渠森.先进复合材料手册[M].北京:机械工业出版社,2003.5
[2]陈华辉,邓海金.现代复合材料[M].北京:中国物资出版社,1998.8
[3]张厚江.碳纤维复合材料钻削加工技术的研究[D].北京:北京航空航天学,1998
[4]吴人洁.复合材料[M].天津大学出版社,2000.12
[5]王荣国,武卫莉.复合材料概论[M].哈尔滨工业大学出版社,1999.8
[6]沃西源,张惠丽.石墨/环氧卫星天线支撑结构研制与质量控制[J].宇航材料工艺, 1997.No.4: 47-51
[7] F-22战斗机专辑[J].航空周刊,1997.(43)
[8]李芝华,郑子樵.碳纤维复合材料应用开发新动向[J].新型炭材料, 1997.NO.4: 15-17
[9] Kopler A, Lystrupa, VormT,The cutting process,chips and cutting forces in machining CFRP,Composites,1983.14(4):371-376
[10] Puv H Y,Hocheng H,Milling foce prediction for FRP,Proceedings of the ASM1993 Materials Congress,1993.(10)
[11] Wern C W,Ramulu M,Investigation of stresses in the orthogonal cutting of FRP,Experiment Mechanics,1996.36(1)
[12]金枝敏明,高桥正行.低速切削碳纤维复合材料表面质量的研究[C].精密工学会秋季学术演讲会,1962.126-131
[13]花崎伸作,藤原顺介.碳纤维复合材料切削刀具的磨损研究[C].日本机械学会论文集,1994.60(1):297-302
[14]花崎伸作,野村昌孝.碳纤维复合材料切削机构的分析[C].日本机械学会论文集,1995.61(3):1163-1168
[15]张厚江,陈五一.碳纤维复合材料切削机理的研究[J].航空制造技术,2004.NO.7: 57-59
[16] Wang D H,Ramulu M,Arola D,Orthogonal cutting mechanisms of graphite/epoxy composite Unidirectional Laminate.Int J Mach Tools Manufact,1995.35(12): 1623-1648
[17]赵建设.碳纤维复合材料钻削温度测试与分析[J].宇航材料工艺,2000.(5):49-51
[18]胡凡.复合材料钻削加工技术的研究[D].北京:北京航空航天大学,1985
[19] J. R. Ferreira,N. L. Coppini,F. Levy Neto,Characteristics of carbon-carbon compositeTurning,Journal of Materials Processing Technology,2001.(109):65-71
[20]张厚江,陈五一.碳纤维复合材料孔壁的微观形态[J].复合材料学报,2000.17(2):98-101
[21]张厚江,陈五一.碳纤维复合材料钻孔出口缺陷的研究[J].机械工程学报,2004.(7):150-155
[22]张伟,张林波.钻削碳纤维复合材料用钻尖刃型分析[J].航空制造工程,1997. (5):26-27
[23]赵建设,李仲平.碳/环氧复合材料钻削力影响因素的研究[J].宇航材料工艺,2004.NO.5:35-38
[24]张卫山.单向石墨/环氧复合材料的纯水射流切割及磨料水射流切割[J].宇航材料工艺,1995. (5):52-56
[25]颜月娥,黄启忠.航空刹车用C/C复合材料的应用与发展[J].新型碳材料,1996.11(3):13-17
[26]于澎,刘根山.不同C/C复合材料飞机刹车盘基本性能的对比分析[J].复合材料学报,2003.20 (3):35-41
[27] K. J. Stout,Development of method for the characterisation of roughness in three dimension,British:Penton press
[28]张厚江,樊锐.复合材料高速钻削试验台的研制[J].航空制造技术, 1998.NO.5:26-27
[29]畏部淳一郎.精密加工—振动切削(基础与应用)[M].北京:机械工业出版社,1985
[30]张云电.超声加工及其应用[M].北京:国防工业出版社,1995.1-11
[31]刘晋春,赵家齐.特种加工(第3版)[M].北京:机械工业出版社,1999.142-155
[32]迁野.音响讲论[M].1983
[33]实吉纯一,菊池喜充.超音波技术便览[M].东京:日刊工业出版社,1978
[34]哈尔滨工业大学编.普通物理[M].哈尔滨工业大学出版社,1985
[35]廖华丽,周军.功率超声加工中超声波发生器的研究[J].煤矿自动化,1999. (6):11-12
[36]闫艳燕.二维超声振动磨削新型陶瓷的磨削机理研究[D].焦作:河南理工大学,2005
[37]陈桂生.超声换能器设计[M].北京:海洋出版社,1984
[38]林仲茂.超声变幅杆的原理和设计[M].北京:科学出版社,1987.84-94
[39]张智星.MATLAB程序设计与应用[M].北京:清华大学出版社,2004.320-322
[40]冯之敬.机械制造工程原理[M].北京:清华大学出版社,2005.50-55
[41]畏部淳一郎.表面加工[M].北京:机械工业出版社,1978
[42]林晶.超声波振动切削机理的微观研究[D].哈尔滨:哈尔滨工程大学,2000
[43]屈维德,唐恒龄.机械振动手册[M].北京:机械工业出版社,2000
[44] Ken-ichi Ishikawa,Hitoshi Suwabe,Tetsuhiro Nishid and Michio Uneda,A study on combined vibration drilling by ultrasonic and low-frequency vibrations for hard and brittle materials,Precision Engineering22(1998):196-205
[45]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
[46]熊国雄.碳纤维复合材料孔加工技术及表面质量分析[D].西安:西北工业大学,2005
[47]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,2005.3
[48]张幼桢.金属切削理论[M].北京:航空工业出版社,1997
[49]侯镇冰,何绍杰,李恕先.固体热传导[M].上海:上海科学技术出版社出版,1984.12(1)
[50]徐鸿钧,徐西鹏.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
[51] L.Li,H.Chang,M.Wang,etal,Temperature Measurement in High Speed Milling Ti6Al4V,Key Engineering Marials Vols,259-260(2004):804-808
[52]孙路华.碳纤维复合材料钻削机理及加工质量的研究[D].广州:华南理工大学,2005
[53]魏金华.复合材料切削机理研究[D].北京:北京航空航天大学,1988
[54]范大鹏.机械制造过程的检测及监控问题研究[D].武汉:华中工学院,1991
[55]王大镇,刘华明.SiCp增强铝基复合材料切削加工中刀-屑摩擦模型及其磨损性能研究[J].摩擦学学报,2000.20(2):85-89
[56]赵建设,李仲平.碳/环氧复合材料钻孔刀具磨损机理的研究[J].宇航材料工艺,2006.NO. 2:68-70
[57]孟宪超.碳纤维复合材料钻孔加工工艺研究[D].大连:大连理工大学,2005
[58] Williams R A,A study of drilling process,Transaction of the ASME,1984:1207-1215
[59]臼井英治.切削磨削加工学[J].机械工业出版社,1971
[60] Geoffery Boothroyd,Fundamentals of metal machining and mqachine,Washington,D.C.1978
[61]郭旭红,朱圣领.陶瓷刀具和PCBN刀具磨损形态的研究[J].机械工程材料,2004.28(11):10-12
[62] N Murdie M,Wood characterization of C-C composite friction films,The European Carbon Conference“CARBON96”NEWCASTE,UK,1996
[63] Hutton T J,McEnancy B,Crelling J,Density profiling studies of wear debris from carbon- carbon composiye aircraft brakes , The European Carbon Conference“CARBON 96”NEWCASTE,UK,1996
[64] Hooton N A,Coureney A L,Effects of oxygen and moisture on corbon-composite frictional 78behavior,Entented Abstrances of 13th Biennial conf Corbon Irvine,1997
[65] D.E.Brehl,T.A.Dow,Review of vibration-assisted machining,Article in press,2007,1-20
[66]赵福令,艾传智.碳碳复合材料切削表面粗糙度的评定方法及评定参数研究[J].计量学报,2006.Vol27,NO.3 207-211
[67] Sreejith P S,Krishnamurthy R,Malhotra S K,Narayanasamy K.Evaluation of PCD tool performance during machining of carbon/phenolic ablative composites,Journal of Materials Processing Technology,2000,104:53-58
[68] Wang X M ,Zhang L C,An experimental investigation into the orthogonal cutting of undirectional fiber reinforced plastics,Intematlonal Journal of Machine Tools & Manufacture,2003,43:1015-1022
[69]张伟,艾启兰.碳纤维复合材料切削后表面微观分析[J].大连轻工业学院学报,1999.Vol.18,NO.3:242-246
[2]陈华辉,邓海金.现代复合材料[M].北京:中国物资出版社,1998.8
[3]张厚江.碳纤维复合材料钻削加工技术的研究[D].北京:北京航空航天学,1998
[4]吴人洁.复合材料[M].天津大学出版社,2000.12
[5]王荣国,武卫莉.复合材料概论[M].哈尔滨工业大学出版社,1999.8
[6]沃西源,张惠丽.石墨/环氧卫星天线支撑结构研制与质量控制[J].宇航材料工艺, 1997.No.4: 47-51
[7] F-22战斗机专辑[J].航空周刊,1997.(43)
[8]李芝华,郑子樵.碳纤维复合材料应用开发新动向[J].新型炭材料, 1997.NO.4: 15-17
[9] Kopler A, Lystrupa, VormT,The cutting process,chips and cutting forces in machining CFRP,Composites,1983.14(4):371-376
[10] Puv H Y,Hocheng H,Milling foce prediction for FRP,Proceedings of the ASM1993 Materials Congress,1993.(10)
[11] Wern C W,Ramulu M,Investigation of stresses in the orthogonal cutting of FRP,Experiment Mechanics,1996.36(1)
[12]金枝敏明,高桥正行.低速切削碳纤维复合材料表面质量的研究[C].精密工学会秋季学术演讲会,1962.126-131
[13]花崎伸作,藤原顺介.碳纤维复合材料切削刀具的磨损研究[C].日本机械学会论文集,1994.60(1):297-302
[14]花崎伸作,野村昌孝.碳纤维复合材料切削机构的分析[C].日本机械学会论文集,1995.61(3):1163-1168
[15]张厚江,陈五一.碳纤维复合材料切削机理的研究[J].航空制造技术,2004.NO.7: 57-59
[16] Wang D H,Ramulu M,Arola D,Orthogonal cutting mechanisms of graphite/epoxy composite Unidirectional Laminate.Int J Mach Tools Manufact,1995.35(12): 1623-1648
[17]赵建设.碳纤维复合材料钻削温度测试与分析[J].宇航材料工艺,2000.(5):49-51
[18]胡凡.复合材料钻削加工技术的研究[D].北京:北京航空航天大学,1985
[19] J. R. Ferreira,N. L. Coppini,F. Levy Neto,Characteristics of carbon-carbon compositeTurning,Journal of Materials Processing Technology,2001.(109):65-71
[20]张厚江,陈五一.碳纤维复合材料孔壁的微观形态[J].复合材料学报,2000.17(2):98-101
[21]张厚江,陈五一.碳纤维复合材料钻孔出口缺陷的研究[J].机械工程学报,2004.(7):150-155
[22]张伟,张林波.钻削碳纤维复合材料用钻尖刃型分析[J].航空制造工程,1997. (5):26-27
[23]赵建设,李仲平.碳/环氧复合材料钻削力影响因素的研究[J].宇航材料工艺,2004.NO.5:35-38
[24]张卫山.单向石墨/环氧复合材料的纯水射流切割及磨料水射流切割[J].宇航材料工艺,1995. (5):52-56
[25]颜月娥,黄启忠.航空刹车用C/C复合材料的应用与发展[J].新型碳材料,1996.11(3):13-17
[26]于澎,刘根山.不同C/C复合材料飞机刹车盘基本性能的对比分析[J].复合材料学报,2003.20 (3):35-41
[27] K. J. Stout,Development of method for the characterisation of roughness in three dimension,British:Penton press
[28]张厚江,樊锐.复合材料高速钻削试验台的研制[J].航空制造技术, 1998.NO.5:26-27
[29]畏部淳一郎.精密加工—振动切削(基础与应用)[M].北京:机械工业出版社,1985
[30]张云电.超声加工及其应用[M].北京:国防工业出版社,1995.1-11
[31]刘晋春,赵家齐.特种加工(第3版)[M].北京:机械工业出版社,1999.142-155
[32]迁野.音响讲论[M].1983
[33]实吉纯一,菊池喜充.超音波技术便览[M].东京:日刊工业出版社,1978
[34]哈尔滨工业大学编.普通物理[M].哈尔滨工业大学出版社,1985
[35]廖华丽,周军.功率超声加工中超声波发生器的研究[J].煤矿自动化,1999. (6):11-12
[36]闫艳燕.二维超声振动磨削新型陶瓷的磨削机理研究[D].焦作:河南理工大学,2005
[37]陈桂生.超声换能器设计[M].北京:海洋出版社,1984
[38]林仲茂.超声变幅杆的原理和设计[M].北京:科学出版社,1987.84-94
[39]张智星.MATLAB程序设计与应用[M].北京:清华大学出版社,2004.320-322
[40]冯之敬.机械制造工程原理[M].北京:清华大学出版社,2005.50-55
[41]畏部淳一郎.表面加工[M].北京:机械工业出版社,1978
[42]林晶.超声波振动切削机理的微观研究[D].哈尔滨:哈尔滨工程大学,2000
[43]屈维德,唐恒龄.机械振动手册[M].北京:机械工业出版社,2000
[44] Ken-ichi Ishikawa,Hitoshi Suwabe,Tetsuhiro Nishid and Michio Uneda,A study on combined vibration drilling by ultrasonic and low-frequency vibrations for hard and brittle materials,Precision Engineering22(1998):196-205
[45]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
[46]熊国雄.碳纤维复合材料孔加工技术及表面质量分析[D].西安:西北工业大学,2005
[47]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,2005.3
[48]张幼桢.金属切削理论[M].北京:航空工业出版社,1997
[49]侯镇冰,何绍杰,李恕先.固体热传导[M].上海:上海科学技术出版社出版,1984.12(1)
[50]徐鸿钧,徐西鹏.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
[51] L.Li,H.Chang,M.Wang,etal,Temperature Measurement in High Speed Milling Ti6Al4V,Key Engineering Marials Vols,259-260(2004):804-808
[52]孙路华.碳纤维复合材料钻削机理及加工质量的研究[D].广州:华南理工大学,2005
[53]魏金华.复合材料切削机理研究[D].北京:北京航空航天大学,1988
[54]范大鹏.机械制造过程的检测及监控问题研究[D].武汉:华中工学院,1991
[55]王大镇,刘华明.SiCp增强铝基复合材料切削加工中刀-屑摩擦模型及其磨损性能研究[J].摩擦学学报,2000.20(2):85-89
[56]赵建设,李仲平.碳/环氧复合材料钻孔刀具磨损机理的研究[J].宇航材料工艺,2006.NO. 2:68-70
[57]孟宪超.碳纤维复合材料钻孔加工工艺研究[D].大连:大连理工大学,2005
[58] Williams R A,A study of drilling process,Transaction of the ASME,1984:1207-1215
[59]臼井英治.切削磨削加工学[J].机械工业出版社,1971
[60] Geoffery Boothroyd,Fundamentals of metal machining and mqachine,Washington,D.C.1978
[61]郭旭红,朱圣领.陶瓷刀具和PCBN刀具磨损形态的研究[J].机械工程材料,2004.28(11):10-12
[62] N Murdie M,Wood characterization of C-C composite friction films,The European Carbon Conference“CARBON96”NEWCASTE,UK,1996
[63] Hutton T J,McEnancy B,Crelling J,Density profiling studies of wear debris from carbon- carbon composiye aircraft brakes , The European Carbon Conference“CARBON 96”NEWCASTE,UK,1996
[64] Hooton N A,Coureney A L,Effects of oxygen and moisture on corbon-composite frictional 78behavior,Entented Abstrances of 13th Biennial conf Corbon Irvine,1997
[65] D.E.Brehl,T.A.Dow,Review of vibration-assisted machining,Article in press,2007,1-20
[66]赵福令,艾传智.碳碳复合材料切削表面粗糙度的评定方法及评定参数研究[J].计量学报,2006.Vol27,NO.3 207-211
[67] Sreejith P S,Krishnamurthy R,Malhotra S K,Narayanasamy K.Evaluation of PCD tool performance during machining of carbon/phenolic ablative composites,Journal of Materials Processing Technology,2000,104:53-58
[68] Wang X M ,Zhang L C,An experimental investigation into the orthogonal cutting of undirectional fiber reinforced plastics,Intematlonal Journal of Machine Tools & Manufacture,2003,43:1015-1022
[69]张伟,艾启兰.碳纤维复合材料切削后表面微观分析[J].大连轻工业学院学报,1999.Vol.18,NO.3:242-246