高聚物粘结炸药模拟材料的超声振动切削试验研究

高聚物粘结炸药广泛运用于武器战斗部领域，由于其低拉伸强度使得传统切削方式加工炸药件时易出现脆性断裂等问题。超声振动切削目前已广泛运用于不包括炸药在内的玻璃、陶瓷及各类合金等难切削材料的加工中。研究中以高聚物粘结炸药模拟材料为试验对象，开展超声振动切削和传统切削的对比试验研究，结果表明超声振动切削可有效降低切削力，各向切削力的下降程度依次为主切削力>切深抗力>进给抗力，具体下降幅度范围为61.75%~67.98%、55.57%~65.56%和31.63%~42.29%；已加工表面的光学显微观测显示超声振动切削获得的表面无明显的切削纹理，同时较传统切削表面灰暗，表明该切削方式在一定程度上有利于缓解切削过程中刀具尖端与炸药材料之间的挤压行为，进而有望获得表面残余应力更小的加工表面，降低挤压生成热和出现切削意外时的风险。由于主切削力和切深抗力的大幅度下降，超声振动切削还可以增强细长杆、薄壁类炸药件的产品制造能力。

An Experimental Study on Ultrasonic Vibration Cutting for Polymer Bonded Explosive Simulants

The polymer bonded explosive (PBX) is an important energetic material widely used in weapon warheads. It is difficult to be machined by using conventional cutting (CC) method, because its low tensile intensity causes brittle fracture. The ultrasonic vibration cutting (UVC) method is a novel technique successfully applied to almost all the difficult to machine materials, such as optical glass, ceramics, intractable alloys, composites and so on, except the explosives. An experimental study on UVC for PBX simulants was presented to compare with CC. Firstly, the contrastive experiments were carried out to investigate the cutting forces in UVC and CC. Secondly, the microscopic morphologies of machined surface were observed on the samples prepared by both UVC and CC method. The experiment results show that the main cutting force in UVC, compared with that in CC, decreases by 61.75% to 67.98%, and the cutting depth resistance and feeding force reduced by 55.57% to 65.56% and 31.63% to 42.29%, respectively; UVC can obtain a less extrusion and lower residual stress surface, and it may reduce the cutting heat. Moreover, UVC method can improve the manufacturing capability for PBX slender rods and thin wall parts.