摘要
目的 研究适用于碳纤维增强树脂基复合材料(CFRP)铣削加工的极限切削速度,并探讨切削参数与切削力、CFRP加工表面质量之间的关系。方法 基于正交试验,利用高速加工中心及自制的金刚石涂层立铣刀对T300 CFRP板进行铣削试验研究,并采用KISTLER测力仪及PG1000显微镜监测切削力及工件表面质量。结果 适度增加切削速度至300 m/min、进给量至400~600 mm/min,可有效减小切削力;通过极差分析可得出切削参数对主切削力的影响程度从大到小为:径向切削深度>轴向切削深度>主轴转速>进给量。当切削力较小且辅以合理的加工参数时(如:切削速度300 m/min、进给量800 mm/min、轴向切深1.5 mm、径向切深3 mm),可有效避免CFRP工件表面产生毛刺、崩边等缺陷,并获得较高的材料去除率。结论 切削速度范围在264~300 m/min时,有助于改善CFRP工件的表面质量。超过此切削速度会导致切削力增大,增加工件损伤的风险。
Carbon fiber reinforced polymer(CFRP)composites exhibit anisotropic properties,high hardness,and low thermal conductivity,which often result in surface defects such as burrs,chipping,and delamination after milling.Many researchers have focused on high-speed dry cutting and milling methods to investigate the cutting force and surface quality of as-machined CFRP. The cutting velocities studied have typically ranged from 100 to 200 m/min. The work aims to employ super-hard diamond-coated tools to investigate whether higher cutting velocities, ranging from 260 to 380 m/min, can effectively enhance the surface quality of CFRP and also comprehensively analyze the relationship between cutting parameters, cutting force, and workpiece surface quality. Initially, hot filament chemical vapor deposition (HFCVD) was utilized to deposit diamond films on WC-Co end mills. Raman spectroscopy and field emission scanning electron microscopy (FESEM) were employed to evaluate the morphology and quality of the diamond films. A milling test study on T300 CFRP laminates was conducted with a GF+ HSM 500 high-speed machining center (up to 42 000 r/min). Cutting force in three directions was measured respectively with a KISTLER 9129AA cutting force dynamometer and DYNOWARE software. The workpiece inspector assessed the surface quality of the machined CFRP and the degree of tool wear with PG1000 cutting tool. Furthermore, in the L4 orthogonal collocation experiments, several controllable factors were considered to analyze the effects of cutting parameters on the cutting force and workpiece surface quality. These factors included spindle speed from 14 000 to 20 000 r/min, feed rate from 200 to 800 mm/min, axial depth of cut from 0.5 to 2 mm, and radial depth of cut from 1.5 to 6 mm. The characterization of the films indicates that the diamond coatings are of high purity and good quality, with a thickness of 6 μm. Results from the milling tests demonstrate that a moderate increase in both cutting velocity (optimal value: 300 m/min) and feed rate (optimal value: 400-600 mm/min) significantly reduces the cutting force. The cutting force increases in each direction with an increase in both axial and radial depth of cut. An analysis of extreme deviation shows the relative effect of four cutting parameters on the magnitude of the primary cutting force, ranks from greatest to least in the order of radial depth of cut, axial depth of cut, spindle speed, and feed rate. From the perspective of achieving better surface quality in CFRP machining, the optimal conditions have been identified. One option is a cutting velocity of 300 m/min, combined with a feed rate of 800 mm/min, and axial and radial depths of cut of 1.5 mm and 3 mm respectively. Alternatively, a cutting velocity of 264 m/min, with a feed rate of 600 mm/min, and axial and radial depths of cut of 1.5 mm and 4.5 mm, respectively, can be used. These parameters help prevent common machining defects such as burrs and chipping on the upper surface of the workpiece, while achieving high machining efficiency. It is noted that a cutting velocity exceeding 300 m/min may lead to high cutting temperatures, surpassing the thermal deformation temperature of the resin. This can cause the resin and the interface to crack firstly, increasing the cutting force required to remove the fibers, which is detrimental to achieving good machining quality.
作者
张韬
邓刘云
李英之
黄孟琼
薛喆
孙方宏
ZHANG Tao;DENG Liuyun;LI Yingzhi;HUANG Mengqiong;XUE Zhe;SUN Fanghong(School of Mechanical Engineering,Wuxi Institute of Technology,Jiangsu Wuxi 214121,China;Zhangjiagang Micro-Nano New Materials Technology Co.,Ltd.,Jiangsu Suzhou 201316,China;School of Mechanical and Power Engineering,Shanghai Jiao Tong University,Shanghai 200240,China)
出处
《表面技术》
北大核心
2025年第6期152-161,共10页
Surface Technology
基金
国家青年自然科学基金资助项目(51605280)
江苏省高校“青蓝工程”中青年学术带头人培养计划(2023)
江苏省自然科学基金项目(BK20201142)。
作者简介
通信作者:张韬。
