超声纵-扭复合铣削钛合金刀具磨损特性研究
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摘要
目的采用超声纵-扭复合振动加工方法,获得较长的刀具使用寿命。方法采用理论建模与不同铣削振动方式,研究刀具磨损特性。通过超景深电子显微镜和粗糙度测试仪,分别对刀具微观形貌、工件表面粗糙度进行了分析;通过不同铣削方式加工钛合金材料,对刀具磨损特性进行了系统分析。结果与普通铣削和超声纵振铣削相比,超声纵-扭铣削方式下,刀具后刀面磨损减小,工件表面粗糙度降低。经测试,当去除面积为6356mm~2时,超声纵-扭复合加工刀具后刀面磨损量VB为103μm,分别比普通和超声纵振加工时降低了38μm和36μm。当去除面积为4530 mm~2时,Ra为1.2μm,普通铣削和超声纵振铣削的Ra则分别为1.62μm和1.38μm。由于超声纵振加工仅仅是在轴向方向实现了分离,后刀面时刻冲击着已加工表面,当去除面积为6356 mm~2时,刀具后刀面磨损量反有超出普通铣削的趋势。结论超声纵-扭复合加工从旋转方向内实现了刀-屑分离,在铣削过程中,极大地减少了刀具后刀面对已加工表面的冲击,从而使得刀具寿命有所延长,为高效加工、难加工材料提供了一种加工方法。
The work aims to obtain longer tool life in ultrasonic longitudinal-torsional vibration milling. The tool wear characteristics were studied by theoretical modeling and different milling vibration modes. The surface topography of the tool and surface roughness of the workpiece were analyzed by the electron microscope(VHX-2000) and surface profiler. Titanium alloys materials were processed by different milling methods and the wear characteristics of tool were analyzed systematically.Compared with the ordinary and ultrasonic longitudinal vibration milling, the ultrasonic longitudinal-torsional vibration milling reduced the wear on the flank surface of tool and improved the roughness of workpiece surface. Through the test, when the removal area was 6356 mm~2, the flank wear under the ultrasonic longitudinal-torsional vibration milling was 103 μm, respectively dropping by 38 μm and 36 μm than that under ordinary and longitudinal ultrasonic milling. When removal area was 4530 mm~2,the roughness Ra was 1.2 μm and Ra for the ordinary and the longitudinal vibration were 1.62 μm and 1.38 μm respectively.Due to the axial separation of ultrasonic longitudinal vibration, the flank continuously impacted the processed surface. The ultrasonic longitudinal vibration method caused more flank wear than the ordinary when removal area reached 6256 mm~2. Ultrasonic longitudinal-torsional vibration machining realizes the actual separation of tool and chip in rotation direction and greatly reduces the impact to the processed surface by flank, thus extending the tool life and providing a new machining method for high-efficient processing and difficult-to-machine-material.
The work aims to obtain longer tool life in ultrasonic longitudinal-torsional vibration milling. The tool wear characteristics were studied by theoretical modeling and different milling vibration modes. The surface topography of the tool and surface roughness of the workpiece were analyzed by the electron microscope(VHX-2000) and surface profiler. Titanium alloys materials were processed by different milling methods and the wear characteristics of tool were analyzed systematically.Compared with the ordinary and ultrasonic longitudinal vibration milling, the ultrasonic longitudinal-torsional vibration milling reduced the wear on the flank surface of tool and improved the roughness of workpiece surface. Through the test, when the removal area was 6356 mm~2, the flank wear under the ultrasonic longitudinal-torsional vibration milling was 103 μm, respectively dropping by 38 μm and 36 μm than that under ordinary and longitudinal ultrasonic milling. When removal area was 4530 mm~2,the roughness Ra was 1.2 μm and Ra for the ordinary and the longitudinal vibration were 1.62 μm and 1.38 μm respectively.Due to the axial separation of ultrasonic longitudinal vibration, the flank continuously impacted the processed surface. The ultrasonic longitudinal vibration method caused more flank wear than the ordinary when removal area reached 6256 mm~2. Ultrasonic longitudinal-torsional vibration machining realizes the actual separation of tool and chip in rotation direction and greatly reduces the impact to the processed surface by flank, thus extending the tool life and providing a new machining method for high-efficient processing and difficult-to-machine-material.
引文
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[17]唐军,赵波.单激励纵-扭复合超声铣削系统研究[J].振动与冲击,2014,34(6):57-62.TANG Jun,ZHAO Bo.A new longitudinal-torsional composite ultrasonic milling system with a single excitation[J].Journal of vibration and shock,2014,34(6):57-62.
[18]唐军,赵波.一种新型纵-扭复合超声振动系统的研究[J].机械科学与技术,2015,34(5):742-747.TANG Jun,ZHAO Bo.Study on a new type of longitudinal-torsional composite ultrasonic vibration system[J].Mechanical science and technology for aerospace engineering,2015,34(5):742-747.
[19]胡林华.钛合金超精切削金刚石刀具磨损及其超声振动抑制的研究[D].哈尔滨:哈尔滨工业大学,2015.HU Lin-hua.Research on diamond tool wear and its ultrasonic vibration suppression in ultraprecision cutting of titanium alloys[D].Harbin:Harbin Institute of Technology,2015.
[2]郑超,魏世丞,梁义,等.钛金属材料干摩擦磨损特性研究[J].装备环境工程,2018,15(4):44-50.ZHENG Chao,WEI Shi-cheng,LIANG Yi,et al.Dry friction wearing characteristics of titanium materials[J].Equipment environmental engineering,2018,15(4):44-50.
[3]冯闯.基于钛合金切削的硬质合金球头刀具磨损研究[D].哈尔滨:哈尔滨理工大学,2015.FENG Chuang.Research on the tool wear mechanism of cemented carbide ball end milling machining titanium alloy[D].Harbin:Harbin University of Science and Technology,2015.
[4]郑勐,董永亨.球头铣刀倾角对硬铝合金工件表面形貌的影响[J].兰州理工大学学报,2016,42(4):36-41.ZHENG Meng,DONG Yong-heng.Effect of inclination-angle of ball-milling cutter on surface morphology of hard aluminium alloy work-piece[J].Journal of Lanzhou University of Technology,2016,42(4):36-41.
[5]魏兆成,王敏杰,王学文,等.球头铣刀曲面多轴加工的刀区半解析建模[J].机械工程学报,2017,53(1):198-205.WEI Zhao-cheng,WANG Min-jie,WANG Xue-wen,et al.A semi-analytical cutter workpiece engagement model for ball end milling of sculptured surface[J].Journal of mechanical engineering,2017,53(1):198-205.
[6]张习芳,郑侃,廖文和,等.超声振动辅助铣削钛合金的表面完整性研究[J].工具技术,2017,51(9):12-16.ZHANG Xi-fang,ZHENG Kan,LIAO Wen-he,et al.Asemi-analytical cutter work-piece engagement model for ball end milling of sculptured surface[J].Journal of mechanical engineering,2017,51(9):12-16.
[7]马超,张建华,陶国灿.超声振动辅助铣削加工钛合金表面摩擦磨损性能研究[J].表面技术,2017,46(8):115-119.MA Chao,ZHANG Jian-hua,TAO Guo-can.Wear and friction properties of titanium alloy surface subject to ultrasonic vibration assisted milling[J].Surface technology,2017,46(8):115-119.
[8]高国富,马星辉,董小磊.超声振动铣削碳纤维复合材料表面特征研究[J].现代制造工程,2009(9):86-89.GAO Guo-fu,MA Xing-hui,DONG Xiao-lei.Research on the surface characteristics in ultrasonic milling of CFRP[J].Modern manufacturing engineering,2009(9):86-89.
[9]PAKTINAT H,AMINI S.Numerical and experimental studies of longitudinal and longitudinal-torsional vibrations in drilling of AISI 1045[J].The international journal of advanced manufacturing technology,2017,94(5-8):2577-2592.
[10]LI Z,ZHANG D,JIANG X,et al.Study on rotary ultrasonic-assisted drilling of titanium alloys(Ti6Al4V)using8-facet drill under no cooling condition[J].Journal of advanced manufacturing technology,2017,90(9-12):3249-3264.
[11]AMINI S,KHOSROJERDI M R,NOSOUHI R.Elliptical ultrasonic-assisted turning tool with longitudinal and bending vibration modes[J].Journal of engineering manufacture,2017,231(8):1389-1395.
[12]AMINIS S,KHOSROJERDI M R,NOSOUHI R.Elliptical ultrasonic-assisted turning tool with longitudinal and bending vibration modes[J].Proceedings of the institution of mechanical engineers,part B:journal of engineering manufacture,2017,231(8):1389-1395.
[13]皮钧,徐西鹏.纵扭共振超声铣削研究[J].中国机械工程,2009,20(10):1163-1169.PI Jun,XU Xi-peng.Research on longitudinal-tersional resonance ultrasonic milling[J].China mechanical engineering,2009,20(10):1163-1169.
[14]童志强,皮钧.纵扭共振旋转超声端铣碳纤维复合材料的试验研究[J].机械科学与技术,2016,35(3):425-430.TONG Zhi-qiang,PI Jun.Experimental study on longitudinal-torsional resonance rotary ultrasonic face milling of CFRP[J].Mechanical science and technology for aerospace engineering,2016,35(3):425-430.
[15]WANG J,ZHANG J,FENG P,et al.Feasibility study of longitudinal-torsional coupled rotary ultrasonic machining of brittle material[J].Journal of manufacturing science&engineering,2018,140(5):051008.
[16]ZHAO G,LIU L,WANG D,et al.Mechanical properties of AISI 1045 steel subjected to combined loads of tension and torsion[J].Experimental techniques,2018,42(4):393-406.
[17]唐军,赵波.单激励纵-扭复合超声铣削系统研究[J].振动与冲击,2014,34(6):57-62.TANG Jun,ZHAO Bo.A new longitudinal-torsional composite ultrasonic milling system with a single excitation[J].Journal of vibration and shock,2014,34(6):57-62.
[18]唐军,赵波.一种新型纵-扭复合超声振动系统的研究[J].机械科学与技术,2015,34(5):742-747.TANG Jun,ZHAO Bo.Study on a new type of longitudinal-torsional composite ultrasonic vibration system[J].Mechanical science and technology for aerospace engineering,2015,34(5):742-747.
[19]胡林华.钛合金超精切削金刚石刀具磨损及其超声振动抑制的研究[D].哈尔滨:哈尔滨工业大学,2015.HU Lin-hua.Research on diamond tool wear and its ultrasonic vibration suppression in ultraprecision cutting of titanium alloys[D].Harbin:Harbin Institute of Technology,2015.