超声振动辅助铣磨加工对CFRP切削力和表面质量的影响

为研究超声振动辅助铣磨加工对碳纤维增强树脂基复合材料(CFRP)切削力和表面质量的影响,建立了超声振动辅助铣磨加工的切削力模型,进行了磨粒运动轨迹、刀具锋利化效果及单颗磨粒切厚的理论分析及试验验证。结果表明:超声振动辅助铣磨加工与传统铣磨加工相比切削力更小、加工质量更好。当每齿进给量从4μm/z增加到8μm/z时,超声振动辅助铣磨加工的切削力增加了44.7%,小于传统铣磨加工的84.9%;同样,当切深从200μm增加到400μm时,超声振动辅助铣磨加工的切削力增加了187.8%,小于传统铣磨加工的209%;在相同加工参数下,超声振动辅助铣磨加工的工件表面与传统铣磨加工相比,树脂涂覆、表面凹坑和纤维拔出量明显减少。 

Effects of ultrasonic vibration-assisted grinding on cutting force and surface quality of CFRP

In order to investigate the effects of ultrasonic vibration-assisted grinding on cutting force and surface quality of carbon fiber reinforced plastics(CFRP), cutting force model of ultrasonic vibration-assisted grinding was proposed. Theoretical analysis and test verification of trajectory of abrasive particle, the effect of sharped cutting edge, maximum undeformed chip thickness were conducted. The result shows that the cutting force is smaller and the surface quality is better in ultrasonic vibration-assisted grinding than in conventional grinding. The cutting force increases by 44.7% in ultrasonic vibration-assisted grinding when the per-tooth feed rises to 8μm/z from 4μm/z. Meanwhile it is 84.9% in conventional grinding. The cutting force increases by 187.8% in ultrasonic vibration-assisted grinding, which is lower than that in the conventional grinding of 209%, when the cutting depth is high up to 400μm from 200μm. Under the same processing parameters, the resin smearing, surface groove and fiber pull-out substantially decrease in ultrasonic vibration-assisted grinding compared with conventional grinding.