加工参数对T800碳纤维增强复合材料铣削质量的影响

doi:10.12382/bgxb.2021.0857

摘要/Abstract

摘要：

增大层厚和增加牺牲层加工工序,是控制大型航空碳纤维复合材料构件形变和装配精度的重要手段,然而如何对其牺牲层进行大余量高效铣削的同时确保无撕裂分层损伤面临挑战。表面柔软的玻璃纤维保护层和内部坚硬的碳纤维复合材料牺牲层因二者的材料性能差异较大,在铣削加工过程中很难同时确保二者均无毛边和分层。为此以某大型航空构件使用的T800碳纤维增强复合材料侧面铣削为例,开展了加工参数对材料铣削质量的影响试验研究,通过分别对硬质合金玉米铣刀、金刚石涂层铣刀、碳纤维专用复合铣刀和双刃聚晶金刚石铣刀4种不同结构形式刀具的铣削力、铣削温度以及加工表面粗糙度进行试验研究,分析了不同加工参数对表面加工质量的影响。试验结果表明:加工表面毛边高度随主轴转速的增加有减小的趋势,随进给速度和径向切深的增加有增大的趋势;较高的铣削温度会引起不同方向的纤维断裂位置发生偏移,导致加工表面粗糙度增大;采用锋利的刃形和多微刃铣削方式,在确保内部碳纤维增强复合材料加工质量的前提下,能够显著改善加工表面的毛边现象,使用左右旋微刃结构的刀具可以使铣削过程更加稳定。

关键词: T800碳纤维增强复合材料, 毛边, 加工参数, 多刃微元铣削

Abstract:

For large carbon fiber composite components used in aviation, increasing layer thickness and adding sacrificial layers are promising measures for controlling the deformation and improving assembly accuracy. However, milling a large number of sacrificial layers with high efficiency and no delamination damage is challenging. It is difficult to ensure that both the soft glass fiber protective layer on the surface and the hard carbon fiber composite sacrificial layers inside are free of burrs and delamination during the milling process. In this study, T800 carbon fiber reinforced polymer is used in a large aviation component as the research object. Milling experiments are carried out to analyze the effects of different machining parameters on milling quality, such as milling force, milling temperature, and machined surface roughness using four different structural tools. The experimental results indicate that the burr height of the machined surface decreases with the increase of spindle speed. When the feed speed and radial cutting depth increase, the burr height tends to increase. Higher milling temperature causes the deviation of fiber fracture position and increases the surface roughness. On the premise of ensuring the machining quality of carbon fiber composites, the sharp edge shape and multi micro edge milling method can significantly restrain the burr damages. The cutter with left-hand and right-hand micro edge structures make the milling process more stable.

Key words: T800 Carbon fiber reinforced polymer/plastic, burr, machining parameters, multi-edge micro element milling

高航, 兰宝华, 许启灏, 陈亮子, 肖光明. 加工参数对T800碳纤维增强复合材料铣削质量的影响[J]. 兵工学报, 2023, 44(4): 994-1005.

GAO Hang, LAN Baohua, XU Qihao, CHEN Liangzi, XIAO Guangming. Influence of Machining Parameters on the Milling Quality of T800 CFRP[J]. Acta Armamentarii, 2023, 44(4): 994-1005.

图/表 19

图1 试验原理

Fig.1 Test principle

图2 试验现场

Fig.2 Test site

图3 试验材料及前21层铺层角度

Fig.3 Test material and paving angle of the first 21 layers

图4 试验刀具

Fig.4 Test tools

表1 刀具几何参数

Table 1 Geometric parameters of the tools

刀具	前角/ (°)	后角/ (°)	左螺旋角/ (°)	右螺旋角/ (°)	齿数	直径/ mm	刀刃区域长度/mm	总长度/ mm
玉米铣刀	6	12	114	64	16	10	28	63
涂层铣刀	8	11	136	76	12	10	22	75
复合铣刀	5	9	128	40	4	10	30	80
PCD铣刀	3	10		86	2	10	16	73

表2 单因素试验参数

Table 2 Single-factor test parameters

水平	n/(r·min^-1)	f/(mm·min^-1)	a_e/mm
1	5000	200	1.0
2	7000	300	1.5
3	8000	400	2.5
4	10000	500	3.0

图5 毛边测量位置

Fig.5 Position for burr measurement

图6 z轴方向毛边高度

Fig.6 z-direction burr height

图7 y轴方向毛边高度

Fig.7 y-direction burr height

图8 表面毛边高度对比(n=8000r/min,f=400mm/min,ae=2.5mm)

Fig.8 Comparison of surface burr heights (n=8000r/min, f=400mm/min, ae=2.5mm)

图9 微刃铣削与整体刃铣削

Fig.9 Micro-edge milling and integral edge milling

图10 受力分析

Fig.10 Force analysis

图11 等效切屑与等效切屑厚度

Fig.11 Equivalent chip and equivalent chip thickness

表3 不同刀具条件下工艺参数对切向比切削能与y轴方向保护层毛边高度的影响

Table 3 Effects of parameters on tangential specific cutting energy and y-direction burr height for different tools

刀具	f=400 mm/min, a_e=1.5 mm	n=8000 r/min, a_e=1.5 mm	n=8000 r/min, f=400 mm/min
压米铣刀
涂层铣刀
复合铣刀
PCD铣刀

图12 4种刀具最大铣削温度

Fig.12 Maximum milling temperature of the four tools

图13 铣削温度红外图像

Fig.13 Infrared image of milling temperature

图14 加工表面粗糙度Sa

Fig.14 Machined surface roughness Sa

图15 铣削温度对纤维断裂的影响[25]

Fig.15 Effects of milling temperature on fiber fracture[25]

图16 加工表面形貌

Fig.16 Machined surface topography

参考文献 26

[1]	HALIM N F H A, ASCROFT H, BARNES S. Analysis of tool wear, cutting force, surface roughness and machining temperature during finishing operation of ultrasonic assisted milling (UAM) of carbon fibre reinforced plastic (CFRP)[J]. Procedia Engineering, 2017, 184: 185-191. doi: 10.1016/j.proeng.2017.04.084 URL
[2]	WANG F J, YIN J W, MA J W, et al. Effects of cutting edge radius and fiber cutting angle on the cutting-induced surface damage in machining of unidirectional CFRP composite laminates[J]. The International Journal of Advanced Manufacturing Technology, 2017, 91(9/10/11/12): 3107-3120. doi: 10.1007/s00170-017-0023-9 URL
[3]	GEIER N. Influence of fibre orientation on cutting force in up and down milling of UD-CFRP composites[J]. The International Journal of Advanced Manufacturing Technology, 2020, 111(3/4): 881-893. doi: 10.1007/s00170-020-06163-3
[4]	NING H F, ZHENG H L, ZHANG S G, et al. Milling force prediction model development for CFRP multidirectional laminates and segmented specific cutting energy analysis[J]. The International Journal of Advanced Manufacturing Technology, 2021, 1130:2437-2445.
[5]	LI M J, HUANG M J, JIANG X G, et al. Study on burr occurrence and surface integrity during slot milling of multidirectional and plain woven CFRPs[J]. The International Journal of Advanced Manufacturing Technology, 2018, 97(1/2/3/4): 163-173. doi: 10.1007/s00170-018-1937-6
[6]	LI H, QIN X D, HUANG T, et al. Machining quality and cutting force signal analysis in UD-CFRP milling under different fiber orientation[J]. The International Journal of Advanced Manufacturing Technology, 2018, 98(9): 2377-2387. doi: 10.1007/s00170-018-2312-3
[7]	秦旭达, 张艳, 李皓, 等. 混联机器人UD-CFRP铣削过程切削力及加工质量分析[J]. 机械科学与技术, 2020, 39(12): 1898-1905.
	QIN X D, ZHANG Y, LI H, et al. Analysis of cutting force and quality for hybrid robot in UD-CFRP milling[J]. Mechanical Science and Technology for Aerospace Engineering, 2020, 39(12): 1898-1905. (in Chinese)
[8]	WANG H J, SUN J, ZHANG D D, et al. The effect of cutting temperature in milling of carbon fiber reinforced polymer composites[J]. Composites Part A:Applied Science and Manufacturing, 2016, 91: 380-387. doi: 10.1016/j.compositesa.2016.10.025 URL
[9]	GEIER N, SZALAY T, BIRÓ I. Trochoid milling of carbon fibre-reinforced plastics (CFRP)[J]. Procedia Cirp, 2018, 77: 375-378. doi: 10.1016/j.procir.2018.09.039 URL
[10]	张勋, 陈燕, 徐九华, 等. 大厚径碳纤维复合材料三维钻削有限元仿真及试验研究[J]. 金刚石与磨料磨具工程, 2020, 40(2): 53-60.
	ZHANG X, CHEN Y, XU J H, et al. Finite element simulation and experimental study on three-dimensional drilling of large diameter carbon fiber composites[J]. Diamond & Abrasives Engineering, 2020, 40(2): 53-60. (in Chinese)
[11]	HE Y L, SHEIKH-AHMAD J, ZHU S W, et al. Cutting force analysis considering edge effects in the milling of carbon fiber reinforced polymer composite[J]. Journal of Materials Processing Technology, 2019, 279: 116541. doi: 10.1016/j.jmatprotec.2019.116541 URL
[12]	周井文, 秦文津, 穆英娟, 等. 碳纤维复合材料铣削与磨削加工对比研究[J]. 金刚石与磨料磨具工程, 2020, 40(4): 76-80.
	ZHOU J W, QIN W J, MU Y J, et al. Comparative study on machining of CFRP by end mill and abrasive router[J]. Diamond & Abrasives Engineering, 2020, 40(4): 76-80. (in Chinese)
[13]	CHEN T, GAO F, LI S Y, et al. Experimental study on cutting tool wear in milling carbon fiber composites with spiral staggered diamond-coated milling cutter[J]. The International Journal of Advanced Manufacturing Technology, 2018, 98(1/2/3/4): 413-419. doi: 10.1007/s00170-018-2297-y
[14]	段春争, 李朋欣, 张方圆, 等. 不同材料刀具铣削碳纤维增强复合材料磨损机理[J]. 哈尔滨工程大学学报, 2018, 39(10): 1655-1660.
	DUAN C Z, LI P X, ZHANG F Y, et al. Wear mechanism of tools made of different materials in milling carbon fiber reinforced plastics[J]. Journal of Harbin Engineering University, 2018, 39(10): 1655-1660. (in Chinese)
[15]	龚佑宏, 韩舒, 晏冬秀, 等. 碳纤维复合材料表面铣削加工性能研究[C]∥第二届上海复合材料学术会议. 上海: 上海市复合材料学会, 上海复合材料产业技术创新战略联盟, 2016: 1-13.
	GONG Y H, HAN S, YAN D X, et al. Experimental study on surface milling performance of CFRP[C]∥Proceedings of the 2nd Shanghai Composite Materials Academic Conference. Shanghai: Shanghai Composite Materials Society, Shanghai Composite Industry Technology Innovation Strategic Alliance, 2016: 1-13. (in Chinese)
[16]	MAEGAWA S, MORIKAWA Y, HAYAKAWA S, et al. Mechanism for changes in cutting forces for down-milling of unidirectional carbon fiber reinforced polymer laminates: modeling and experimentation[J]. International Journal of Machine Tools & Manufacture, 2016, 100: 7-13. doi: 10.1016/j.ijmachtools.2015.10.003 URL
[17]	ZHANG L C, ZHANG H J, WANG X M. A force prediction model for cutting unidirectional fibre-reinforced plastics[J]. Machining Science and Technology, 2001, 5(3): 293-305. doi: 10.1081/MST-100108616 URL
[18]	万敏, 李少恩, 原恒, 等. CFRP铣削力建模研究[J]. 南京航空航天大学学报, 2019, 51(3): 272-280.
	WAN M, LI S E, YUAN H, et al. Cutting force modeling in milling of CFRP[J]. Journal of Nanjing University of Aeronautics & Astronautics, 2019, 51(3): 272-280. (in Chinese)
[19]	GHAFARIZADEH S, CHATELAIN J, LEBRUN G. Finite element analysis of surface milling of carbon fiber-reinforced composites[J]. The International Journal of Advanced Manufacturing Technology, 2016, 87(1/2/3/4): 399-409. doi: 10.1007/s00170-016-8482-y URL
[20]	XU X F, JIN X L. 3-D finite element modeling of sequential oblique cutting of unidirectional carbon fiber reinforced polymer[J]. Composite Structures, 2021, 256: 113127. doi: 10.1016/j.compstruct.2020.113127 URL
[21]	OZKAN D, PANJAN P, GOK M S, et al. Investigation of machining parameters that affects surface roughness and cutting forces in milling of CFRPs with TiAlN and TiN coated carbide cutting tools[J]. Materials Research Express, 2019, 6(9): 95616. doi: 10.1088/2053-1591/ab30de URL
[22]	周井文, 陈燕, 傅玉灿, 等. 进给速度对不同纤维方向CFRP铣削表面形貌的影响[J]. 复合材料学报, 2015, 32(2): 370-377.
	ZHOU J W, CHEN Y, FU Y C, et al. Influence of feed speed on surface morphology of CFRP with different fiber directions during milling[J]. Acta Materiae Compositae Sinica, 2015, 32(2): 370-377. (in Chinese)
[23]	殷俊伟, 贾振元, 王福吉, 等. 基于CFRP切削过程仿真的面下损伤形成分析[J]. 机械工程学报, 2016, 52(17): 58-64. doi: 10.3901/JME.2016.17.058
	YIN J W, JIA Z Y, WANG F J, et al. FEM simulation analysis of subsurface damage formation based on continuously cutting process of CFRP[J]. Journal of Mechanical Engineering, 2016, 52(17): 58-64. (in Chinese) doi: 10.3901/JME.2016.17.058
[24]	XIAO J Z, GAO C Y, KE Y L. An analytical approach to cutting force prediction in milling of carbon fiber reinforced polymer laminates[J]. Machining Science and Technology, 2018, 22(6): 1012-1028. doi: 10.1080/10910344.2018.1449214 URL
[25]	JIA Z Y, FU R, WANG F J, et al. Temperature effects in end milling carbon fiber reinforced polymer composites[J]. Polymer Composites, 2018, 39(2): 437-447. doi: 10.1002/pc.v39.2 URL
[26]	LI H N, WANG J P, WU C Q, et al. Damage behaviors of unidirectional CFRP in orthogonal cutting: a comparison between single- and multiple-pass strategies[J]. Composites Part B:Engineering, 2020, 185: 107774. doi: 10.1016/j.compositesb.2020.107774 URL

编辑推荐 0

Metrics

阅读次数

全文

230

HTML			PDF

最新录用	在线预览	正式出版	最新录用	在线预览	正式出版
0	0	5	82	0	143

来源	本网站	其他网站

次数	159	71
比例	69%	31%

摘要

316

最新录用	在线预览	正式出版

85	0	231

来源	本网站	其他网站

次数	118	198
比例	37%	63%