CFRP超声振动套磨钻孔高效排屑机理和实验

李哲; 王新; 张毅; 侯博; 张德远

doi:10.13700/j.bh.1001-5965.2018.0620

CFRP超声振动套磨钻孔高效排屑机理和实验

doi: 10.13700/j.bh.1001-5965.2018.0620

李哲¹,
王新¹,
张毅¹,
侯博¹,
张德远^2, ,

1.
航天材料及工艺研究所, 北京 100076
2.
北京航空航天大学机械工程及自动化学院, 北京 100083

详细信息

作者简介:
李哲男, 博士, 工程师。主要研究方向:复合材料等难加工材料及其构件先进制造及高效精密加工装配与装备技术、数字智能化设计制造与装配技术、振动切削与功率超声技术

张德远男, 博士, 教授, 博士生导师。主要研究方向:复合材料等难加工材料及其构件高效精密加工与装配技术、振动切削与功率超声技术

通讯作者:
张德远. E-mail: zhangdy@buaa.edu.cn

中图分类号: V19
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出版历程
- 收稿日期: 2018-10-29
- 录用日期: 2019-02-16
- 网络出版日期: 2020-01-20

Mechanism and experiment on high-efficiency chip removal in ultrasonic vibration core drilling of CFRP

LI Zhe¹,
WANG Xin¹,
ZHANG Yi¹,
HOU Bo¹,
ZHANG Deyuan^{2
, ,}

1.
Aerospace Research Institute of Materials & Processing Technology, Beijing 100076, China
2.
School of Mechanical Engineering and Automation, Beihang University, Beijing 100083, China

More Information

Corresponding author: ZHANG Deyuan. E-mail: zhangdy@buaa.edu.cn

摘要

摘要:
针对碳纤维增强复合材料（CFRP）在普通套磨钻孔（CCD）过程中，切屑粉尘粘刀和料芯堵刀导致的排屑效果较差而影响套磨加工效率和加工质量的问题，采用超声振动套磨钻孔（UVCD）新技术进行了CFRP高效套磨钻孔的基础理论和实验研究。从理论上分析了CFRP超声振动套磨钻孔原理和高效排屑机理，同时结合所设计的超声振动气钻和车床平台实验验证了CFRP超声振动套磨钻孔的高效排屑钻孔效果。结果表明：相比于CFRP普通套磨钻孔，超声振动套磨钻孔极大提高了切屑粉尘和料芯的排屑效果，有效防止了切屑粉尘粘刀和料芯堵刀现象，明显降低了12%~20%的钻削力、16%~24%的切削温度和33%~39%的孔表面粗糙度，明显改善了CFRP孔加工质量并且延长了套磨刀具使用寿命。
- 碳纤维增强复合材料(CFRP) /
- 金刚石套磨刀具 /
- 超声振动套磨钻孔(UVCD) /
- 高效排屑 /
- 加工质量
Abstract:
To solve the problems of poor chip removal effects like the chip adhesion and rod jamming of core drill tool that would have a significantly negative influence on machining efficiency and machining quality during common core drilling (CCD) process of carbon fiber reinforced plastics (CFRP) using a core drill, the novel ultrasonic vibration core drilling (UVCD) technology was employed so as to carry out the basic theory and experiment study of high-efficiency core drilling CFRP. The core drilling principle and high-efficiency chip removal mechanism of UVCD were analyzed by theoretical method, meanwhile the machining effects of high-efficiency chip removal in UVCD of CFRP was verified by experimental method with a designed ultrasonic vibration air drill and lathe platform. The results indicate that compared with the CCD of CFRP, in the UVCD process, the chip removal effects of chip and rod are greatly improved, the problems of chip adhesion and rod jamming of core drill tool are effectively prevented, the thrust force, cutting temperature and hole surface roughness decrease by 12%-20%, 16%-24% and 33%-39% respectively, the machining quality of CFRP hole is obviously improved, and the tool life of core drill will be evidently prolonged.
- carbon fiber reinforced plastics (CFRP) /
- diamond core drill /
- ultrasonic vibration core drilling (UVCD) /
- high-efficiency chip removal /
- machining quality

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图 1 CFRP超声振动套磨原理示意图

Figure 1. Schematic of UVCD principle of CFRP

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图 2 UVCD过程套刀单颗磨粒运动轨迹示意图

Figure 2. Schematic of motion trajectory of single grain on diamond core drill in UVCD process

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图 3 CCD和UVCD的合速度与合加速度对比

Figure 3. Comparison of synthetic cutting velocity and acceleration in CCD and UVCD

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图 4 CCD连续切削过程套刀前端面单颗磨粒切削及切屑黏附过程模型

Figure 4. Model of single grain cutting and chip adhesion of core drill end face in CCD with continuous cutting process

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图 5 UVCD分离切削过程套刀前端面单颗磨粒切削及高效排屑过程模型

Figure 5. Model of single grain cutting and high-efficiency chip removal of core drill end face in UVCD with separated cutting process

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图 6 CCD连续切削过程套刀侧壁单颗磨粒切削及切屑黏附过程模型

Figure 6. Model of single grain cutting and chip adhesion of core drill lateral face in CCD with continuous cutting process

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图 7 UVCD分离切削过程套刀侧壁单颗磨粒切削及高效排屑过程模型

Figure 7. Model of single grain cutting and high-efficiency chip removal of core drill lateral face in UVCD with separated cutting process

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图 8 周期性接触-分离的UVCD切削过程的空气流动和切屑排出模型

Figure 8. Model of air and chip dredged to flow and eject in UVCD with periodic contact and separation cutting process

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图 9 UVCD提高料芯排出和防止料芯堵塞套磨刀具模型

Figure 9. Model of improved rod removal and prevention of rod jammed into core drill in UVCD

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图 10 实验中套刀及其磨粒分布

Figure 10. Diamond core drill in experiment and associated grain distribution

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图 11 CFRP超声振动套磨实验平台

Figure 11. Experimental platform of UVCD of CFRP

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图 12 CFRP普通套磨和超声振动套磨在第1、5和8个孔后的排屑效果对比

Figure 12. Comparison of removal effects of chip and rod after the first, fifth and eighth drilled hole in CCD and UVCD of CFRP

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图 13 CFRP普通套磨和超声振动套磨的钻削力与切削温度对比

Figure 13. Comparison of thrust force and cutting temperature in CCD and UVCD of CFRP

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图 14 CFRP普通套磨和超声振动套磨在第8个孔后刀具磨粒微观观察

Figure 14. Microscopic observation of tool grain after the eighth drilled hole in CCD and UVCD of CFRP

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图 15 CFRP普通套磨和超声振动套磨的孔表面粗糙度对比

Figure 15. Comparison of surface roughness in CCD and UVCD of CFRP

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图 16 CFRP普通套磨和超声振动套磨在第1、5和8个孔后表面质量微观观察

Figure 16. Microscopic observation of surface quality after the first, fifth and eighth drilled hole in CCD and UVCD of CFRP

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表 1 CFRP普通套磨和超声振动套磨实验条件

Table 1. Experimental conditions in CCD and UVCD of CFRP

参数	CCD	UVCD
钻孔直径/mm	7.5	7.5
钻孔深度/mm	5	5
磨粒粒径/mm	0.25	0.25
转速/(r·min^-1)	6 000	6 000
进给/(mm·s^-1)	0.5	0.5
超声振动频率/kHz	0	21.5
振幅/μm	0	7.5
注：CCD与UVCD刀具类型均为套刀，均不冷却。

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