高速超声振动铣削钛合金实验研究

韩雄; 孙哲飞; 耿大喜; 张德远

doi:10.13700/j.bh.1001-5965.2021.0519

高速超声振动铣削钛合金实验研究

doi: 10.13700/j.bh.1001-5965.2021.0519

韩雄^{1, 2},
孙哲飞¹,
耿大喜^1, ,,
张德远¹

1.
北京航空航天大学机械工程及自动化学院，北京 100191
2.
成都飞机工业（集团）有限责任公司，成都 610091

详细信息

通讯作者:
E-mail：gengdx@ buaa.edu.cn

中图分类号: V261.92
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- 被引次数: 0
出版历程
- 收稿日期: 2021-09-16
- 录用日期: 2021-11-05
- 网络出版日期: 2022-01-18
- 整期出版日期: 2023-07-31

Experiment research on high-speed ultrasonic vibration milling of titanium alloy

HAN Xiong^{1, 2},
SUN Zhefei¹,
GENG Daxi^{1
, ,},
ZHANG Deyuan¹

1.
School of Mechanical Engineering and Automation，Beihang University，Beijing 100191，China
2.
Chengdu Aircraft Industrial (Group) Co.，Ltd.，Chengdu 610091，China

More Information

Corresponding author: E-mail：gengdx@ buaa.edu.cn

摘要

摘要:
针对钛合金在普通铣削（CM）时因切削速度低而面临的切削力大、薄壁工件变形大、加工效率低、刀具磨损严重等问题，采用高速超声振动铣削（HUVM）方法加工钛合金，实验研究其加工表面质量和切削力。从运动学角度出发对HUVM方法进行运动学分析。搭建包括超声振动系统、加工系统及测量系统在内的高速超声振动铣削实验平台。采用单因素实验对比CM和HUVM这2种方法对钛合金加工切削力和表面质量的影响规律。研究结果表明：与CM加工相比，HUVM加工可以使切削力降低32.6%～35.3%。并且HUVM加工表面粗糙度虽略有增加，但是表面结构可以更加均匀；此外，HUVM加工表面残余应力均为压应力，其绝对值随着每齿进给量和切削速度的增大而降低，而CM加工表面残余应力为拉应力。
- 超声振动 /
- 铣削 /
- 表面粗糙度 /
- 残余应力 /
- 切削力
Abstract:
Conventional milling (CM) causes problems for titanium alloys, such as high cutting forces, large deformation of thin-walled workpieces, low processing efficiency, and severe tool wear due to low cutting speeds. To address these problems, a new method of high-speed ultrasonic vibration milling (HUVM) is adopted to machine titanium alloys. Their surface quality and the cutting force are also examined through experiments. The kinematic equation of HUVM is constructed. An HUVM experimental platform including ultrasonic vibration system, machining system and measurement system is built. Single factor experiments are carried out to explore the effects of CM and HUVM on the surface quality and cutting force. The experimental results show that compared with CM, HUVM could generate more uniform surface structure with increased surface roughness. Unlike CM with residual tensile stress of the machined surfaces, HUVM has residual compressive stress with its value decreasing with the increase of feed per tooth and cutting speed. Moreover, HUVM could reduce cutting force by 32.6%~35.3% compared to CM.
- ultrasonic vibration /
- milling /
- surface roughness /
- residual stress /
- cutting force

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图 1 HUVM加工过程示意图

Figure 1. Schematic of HUVM process

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图 2 铣刀4个刀齿运动轨迹

Figure 2. Motion trace of four cutter teeth

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图 3 实验装置

Figure 3. Experimental setup

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图 4 三向切削力信号

Figure 4. Three-way cutting force signal

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图 5 切削速度与平均切削力关系

Figure 5. Relationship between average cutting speed, feed force, and tangential force

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图 6 平均切削力与每齿进给量关系

Figure 6. Relationship between average feed force, tangential force and feed rate per tooth

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图 7 表面粗糙度与每齿进给量关系

Figure 7. Relationship between surface roughness and feed rate per tooth

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图 8 加工表面宏观形貌

Figure 8. Macro-morphology of machined surface

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图 9 加工表面微观形貌

Figure 9. Micro-morphology of machined surface

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图 10 表面粗糙度和切削速度关系

Figure 10. Relationship between surface roughness and cutting speed

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图 11 残余应力和每齿进给量关系（v_f=80 m/min）

Figure 11. Relationship between residual stress and feed rate per tooth（v_f=80 m/min）

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图 12 残余应力和切削速度关系（f_z=0.015 mm/齿）

Figure 12. Relationship between residual stress and cutting speed （ f_z=0.015 mm/齿）

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表 1 钛合金化学成分^[13]

Table 1. Chemical composition of titanium alloy^[13]

元素	Al	V	Fe	C	N	H	O	Ti
占比/%	5.5~ 6.75	3.5~ 4.5	<0.25	<0.08	<0.05	<0.01	<0.2	余量

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表 2 实验参数设置

Table 2. Experimental parameter settings

参数	数值
每齿进给量f_z/(mm·齿⁻¹)	0.015,0.03,0.045,0.06,0.075,0.09, 0.105,0.12,0.135
切削速度v/(m·min⁻¹)	80,100,120,140,160
径向切宽/mm	0.2
轴向切深/mm	8
铣削类型	CM, HUVM
振动频率/Hz	17880
振动幅值/μm	A=15.8, B=13.6

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