碳化硅颗粒增强铝基复合材料高速铣削棱边形-性一体化形成机理与工艺研究

As the core component of phased array radar, the geometric precision and surface quality of T/R modules directly affect the electromagnetic interference between receiving and transmitting channels. For the high speed milling of T/R modules, this project will propose a processing method of the edge of shape-performance integration based on the geometry and surface integrity. The aim is to establish the relationship between the geometric precision with the integrity of the edge and the cutting process. In this project, the experimental methods will be used to construct the multi field coupled constitutive model of SiCp/Al composites considering the effect of particle size and volume fraction; using finite element method to simulate the milling process of SiCp/Al composites, to analyze the edge burr, the edge collapse and the milling forces; using finite element simulation and experimental methods, to study the PCD cutting tool wear model and optimize tool structure, in order to obtain the optimization design method of milling cutter for SiCp/Al composite material; using experimental methods, analyze the effects of milling path and tool cutting order on edge burr and edge collapse, and give a quantitative representation of geometric model; using two dimensional ultrasonic vibration milling method to analyze the causes of defects, and establish the mapping relationship between the ultrasonic vibration mode and the removal mechanism of SiCp/Al composites. This project can provide experimental and theoretical reference for the high speed milling of T/R modules.

作为相控阵雷达的核心部件，T/R组件的棱边几何精度和表面质量直接影响收发通道内部之间的电磁干扰。本项目针对T/R组件的高速铣削，提出基于棱边几何特征和表面完整性的形-性一体化工艺方法，目的是建立棱边几何精度与完整性同刀具与工艺之间的联系。本项目运用实验方法构建考虑颗粒尺度与体积分数影响的SiCp/Al复合材料多场耦合本构关系模型；采用有限元方法模拟SiCp/Al复合材料的铣削过程，以分析棱边毛刺和崩边以及铣削力的变化；运用有限元仿真和实验方法，研究PCD刀具的磨损模型，对刀具结构优化设计，以获得SiCp/Al复合材料铣削刀具优化设计方法；运用实验方法，分析铣削路径和刀具出刀顺序对棱边毛刺和崩边的影响，提出其定量表征几何模型；采用二维超声振动复合铣削方法，分析缺陷成因，建立超声振动模态与SiCp/Al复合材料去除机理之间的映射关系。本项目可为T/R组件的高速铣削提供实验与理论参考依据。

SiCp/Al 复合材料以其优异的物理力学性能，被广泛应用于航空航天等高技术领域，但其难切削加工性限制了其应用及发展。本项目针对低体积分数SiCp/Al复合材料的高速铣削加工，探究棱边几何特征和表面完整性的形-性一体化工艺方法，以优化刀具及加工工艺为手段提高棱边几何精度及表面完整性。本项目根据材料特有属性建立有限元仿真模型开展了不同切削条件下棱边及表面缺陷产生过程与形成规律研究，并通过具体实验验证了仿真结果的可靠性；从刀具优化考虑，进行了刀具刃口钝圆及刀具几何结构对棱边及表面质量影响的实验研究，初步探究了刀具刃口半径-颗粒间的尺寸效应，提出了刀具优化方法；从加工工艺考虑，研究了超声辅助铣削SiCp/Al复合材料棱边及表面的形成机理并提出振幅的大小直接影响材料加工精度；进行了液氮低温铣削实验，对比干切削实验结果得到SiCp/Al 复合材料不适用于低温加工工艺。本项目从宏微观角度，以实验-理论-仿真为手段系统性的对SiCp/Al 复合材料进行切削加工性研究，对设计合适的铣削刀具及优化加工工艺的开展具有重大促进作用。