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CFRP旋转超声辅助钻削的缺陷抑制机理及实验研究

邵振宇 姜兴刚 张德远 耿大喜 李少敏 刘大鹏

邵振宇, 姜兴刚, 张德远, 等 . CFRP旋转超声辅助钻削的缺陷抑制机理及实验研究[J]. 北京航空航天大学学报, 2019, 45(8): 1613-1621. doi: 10.13700/j.bh.1001-5965.2018.0713
引用本文: 邵振宇, 姜兴刚, 张德远, 等 . CFRP旋转超声辅助钻削的缺陷抑制机理及实验研究[J]. 北京航空航天大学学报, 2019, 45(8): 1613-1621. doi: 10.13700/j.bh.1001-5965.2018.0713
SHAO Zhenyu, JIANG Xinggang, ZHANG Deyuan, et al. Defect suppression mechanism and experimental study on rotary ultrasonic-assisted drilling of CFRP[J]. Journal of Beijing University of Aeronautics and Astronautics, 2019, 45(8): 1613-1621. doi: 10.13700/j.bh.1001-5965.2018.0713(in Chinese)
Citation: SHAO Zhenyu, JIANG Xinggang, ZHANG Deyuan, et al. Defect suppression mechanism and experimental study on rotary ultrasonic-assisted drilling of CFRP[J]. Journal of Beijing University of Aeronautics and Astronautics, 2019, 45(8): 1613-1621. doi: 10.13700/j.bh.1001-5965.2018.0713(in Chinese)

CFRP旋转超声辅助钻削的缺陷抑制机理及实验研究

doi: 10.13700/j.bh.1001-5965.2018.0713
基金项目: 

国家自然科学基金 51475031

中国博士后科学基金 2018M631301

详细信息
    作者简介:

    邵振宇  男, 博士研究生。主要研究方向:难加工材料高效加工技术、振动切削与功率超声技术

    耿大喜  男, 博士。主要研究方向:难加工材料高效振动制孔技术与装备

    通讯作者:

    耿大喜, E-mail: gengdx@buaa.edu.cn

  • 中图分类号: V261.92

Defect suppression mechanism and experimental study on rotary ultrasonic-assisted drilling of CFRP

Funds: 

National Natural Science Foundation of China 51475031

China Postdoctoral Science Foundation 2018M631301

More Information
  • 摘要:

    针对碳纤维增强树脂基复合材料(CFRP)在普通切削(CD)过程中因切削力及扭矩较大而产生的分层撕裂、孔壁纤维损失等缺陷,采用了旋转超声辅助钻削(RUAD)制孔方法。首先,分析了CFRP CD的孔缺陷类型及产生机理,并结合超声振动加工的特性,给出了RUAD的孔缺陷抑制机理。然后,搭建了包含非接触式感应供电旋转超声振动系统、立式加工中心和测力系统的实验平台。最后,在相同的工艺参数下,对比了CD和RUAD两种工艺下的切削力和扭矩、孔缺陷及孔壁质量。实验结果表明:相对CD,RUAD的切削力和扭矩分别降低41.46%~46.32%和41.61%~48.94%,且CFRP孔出入口及孔壁分层撕裂、纤维损失等缺陷得到了有效抑制,极大地改善了CFRP的钻孔质量。实验结果有效地验证了CFRP钻孔缺陷产生机理及超声振动抑制机理的正确性,RUAD可以用于CFRP低损伤制孔。

     

  • 图 1  RUAD原理示意图

    Figure 1.  Schematic of RUAD principle

    图 2  普通钻削CFRP时横刃和主切削刃连续切削引起分层撕裂缺陷原理图

    Figure 2.  Schematic of delamination and tearing induced by chisel edge and major cutting edge of continuous cutting during conventional drilling of CFRP

    图 3  RUAD横刃和主切削刃的分离断续脉冲式切削抑制CFRP孔缺陷形成机理

    Figure 3.  Defect suppression mechanism of separate intermittent impulse cutting model of chisel edge and major cutting edge during RUAD of CFRP hole

    图 4  实验中刀具几何视图

    Figure 4.  Tool geometry in experiment

    图 5  普通麻花钻几何视图

    Figure 5.  Conventional twist drill geometry

    图 6  实验平台

    Figure 6.  Experimental platform

    图 7  钻尖振幅测量原理及测量结果

    Figure 7.  Principle and result of drill tip vibration amplitude measurement

    图 8  CD和RUAD CFRP平均切削力和扭矩对比

    Figure 8.  Comparison of average cutting force and torque between CD and RUAD

    图 9  CD和RUAD CFRP孔入口边缘形貌对比

    Figure 9.  Comparison of edge morphologies of CFRP hole entrance between CD and RUAD

    图 10  CD和RUAD CFRP孔入口分层因子对比

    Figure 10.  Comparison of delamination factor of CFRP hole entrance between CD and RUAD

    图 11  CD和RUAD CFRP孔壁SEM照片

    Figure 11.  SEM images of drilled hole surface morphologies of CFRP for CD and RUAD

    图 12  CD和RUAD CFRP孔出口形貌对比

    Figure 12.  Comparison of edge morphologies of CFRP hole exit between CD and RUAD

    表  1  CFRP工件材料属性

    Table  1.   Material properties of CFRP workpiece

    属性 数值
    CFRP密度/(kg·m-3) 1 520
    铺层厚度/mm 0.2
    碳纤维硬度HRC 53~65
    碳纤维密度/(kg·m-3) 1 760
    碳纤维的弹性模量/GPa 230
    碳纤维的拉伸强度/GPa 4 850
    碳纤维的泊松比 0.3
    环氧树脂基体密度/(kg·m-3) 1 190
    环氧树脂基体弹性模量/GPa 2.7
    环氧树脂基体抗拉强度/MPa 80~85
    环氧树脂基体泊松比 0.35
    下载: 导出CSV

    表  2  刀具几何参数

    Table  2.   Tool geometric parameters

    参数 数值
    直径/mm 7.5
    总长度/mm 98
    顶角/(°) 118
    刃前角/(°) 10
    刃后角/(°) 10
    螺旋角/(°) 20
    横刃宽度/mm 0.2
    主切削刃宽度/mm 1
    下载: 导出CSV

    表  3  实验条件和工艺参数

    Table  3.   Experimental conditions and process parameters

    条件与参数 CD RUAD
    刀具材料 硬质合金 硬质合金
    刀具涂层
    冷却
    钻孔直径/mm 7.5 7.5
    钻孔深度/mm 5.0 5.0
    主轴转速/(r·min-1) 1 500,2 000,2 500, 3 000 1 500,2 000,2 500, 3 000
    每转进给量/(mm·r-1) 0.01 0.01
    频率/kHz 0 18.687
    振幅/μm 0 10.0
    下载: 导出CSV
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出版历程
  • 收稿日期:  2018-12-03
  • 录用日期:  2019-02-16
  • 刊出日期:  2019-08-20

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