碳纤维增强复合材料螺旋铣孔切削力及加工质量研究

针对传统钻孔方法加工复合材料时易导致分层、撕裂等缺陷的问题,采用螺旋铣作为新的制孔技术,根据飞机装配现场的实际加工条件,构建以机器人为移动载体、螺旋铣孔终端执行器为加工单元、螺旋铣孔专用刀具为切削工具的加工系统,采用该加工系统对碳纤维增强复合材料(CFRP)螺旋铣孔关键工艺参数进行正交试验,并讨论了刀具主轴转速、每齿进给量和轴向切削深度等工艺参数对切削力的影响规律;通过对加工缺陷的监测,探讨了切削力与CFRP分层、撕裂等缺陷之间的关系;最后对工艺参数进行优化,经试验验证,优化后轴向切削力较优化前降低26%以上,孔入口及出口处均无撕裂、毛刺,加工质量最优。

Study on cutting force and machining quality of orbital drilling for CFRP

Conventional drilling of composites always results in fiber delamination and tear, as a new borehole processing method, orbital drilling has many advantages for composites processing.Considering the practical processing condition in aircraft assembly site, one drilling system including robot as moving carrier, orbital drilling terminal actuators as processing unit and orbital drilling tool was established.The orbital drilling parameters orthogonal test of carbon fiber reinforced plastics (CFRP) was carried out based on this system, and the effects of tool spindle speed, feed per tooth and axial feed depth on cutting force were deeply analyzed.With the defects inspection results, the relationship between cutting force and defects, such as delamination and tear, were investigated.At last, the optimal set of process parameters was obtained.It is verified that thrust force decreases more than 26% after optimation and there are hardly tear and burr formation around the hole exit and entrance, which indicates a better machining quality.