航空异质构件连接孔加工损伤产生机制及高质量制孔关键技术

In order to achieve high-reliability and long-life connecting between different-material aviation-components, the primary job is the obtention of high quality connecting-hole. Connecting-hole machining between different-material components is a great challenge in aviation industry. The properties of the two materials are usually far away from each other, and the hole should be machining in one process. Therefore, serious damage often generated during machining for its unique machining process. In this work, the connecting-hole between composite component and metal component is investigated. The objective of this work is to study the damage generation during hole-making and high quality machining technology. The mechanism of material removal and the changing of composite material properties during machining are studied at first. Based on this, the interaction effect between hole-making processes of the two materials is discussed, as well as the variation of tool wear and breakage. Furthermore, the influence of interaction effect or tool wear on both machining damage and machining accuracy is analysed. After this, a strategy used to assess machining quality is proposed, which based on the variation of mechanical properties of connecting. The importance of this research lies in not only improving the machining theory during cutting of different materials in one process, but also helpful to promoting the flexible assembly technology and the connecting performance between different material components.

连接孔的高质量加工是实现航空异质构件高可靠、长寿命连接的基础和关键。异质构件一体化制孔的加工需求及材料性质的巨大差异，导致其连接孔的加工面临着诸多与传统单一材料加工完全不同的难题和挑战。本项目以航空复合材料构件与金属构件的高质量连接孔加工为主要研究对象，在对制孔过程中复合材料性能演变机制和材料去除机理研究的基础上，揭示制孔过程干涉、刀具磨/破损规律等关键因素对加工损伤及制孔精度的影响机制，并通过建立基于连接区域力学性能的加工质量评价模型，探讨高质量连接孔的高效加工关键技术。项目的研究成果不仅体现在对异质材料一体化加工基础理论的推动作用，而且对促进航空异质构件高效装配技术的发展以及提高连接组件的高使役性能均具有重要意义。

航空结构件的连接装配水平是衡量世界各国航空制造能力的重要标志之一。“一代材料、一代飞机”，复合材料在飞行器上的使用量已经成为衡量飞行器先进性的关键要素。同时，在飞行器各类承力构件中，钛合金等金属材料依然发挥着不可替代的作用。复合材料结构件与金属承力结构件必然将在航空制造领域长期共存。连接孔的高质量加工是实现航空异质构件高可靠、长寿命连接的基础和关键。异质构件一体化制孔的加工需求及材料性质的巨大差异，导致其连接孔的加工面临着诸多与传统单一材料加工完全不同的难题和挑战。本项目以航空复合材料构件与金属构件的高质量连接孔加工为主要研究对象，在对制孔过程中复合材料性能演变机制和材料去除机理研究的基础上，揭示了异质构件连接孔加工过程中的损伤产生机理和关键因素影响规律，提出了异质材料界面的切削温度及应力畸变是导致硬质合金刀具磨/破损产生的关键，建立了加工几何精度与材料种类、切削方法之间的映射关系，提出了基于螺旋铣削补偿方法的制孔关键技术。项目的研究成果不仅体现在对异质材料一体化加工基础理论的推动作用，而且对促进航空异质构件高效装配技术的发展以及提高连接组件的高使役性能均具有重要意义。