航空CFRP/Ti叠层材料连续制孔中热累积效应控制的基础研究

The aerospace composite/metal laminated structural parts in the national aircraft industry have urgent demand in the high-quality and high-efficiency sequential automatic hole-making process. Aiming at the thermal-dominated problems of rapid tool wear, frequent tool change, poor drilling efficiency and prone to damage, etc. during sequential hole-making process, this project set drilling temperature variation characteristic of sequential hole-making process as the research object, and on this basis to carry out further breakthrough study in the correlation mechanism between the tool wear, hole-making temperature and its damage. The correlation relationship of Temperature-Fracture-Wearing is studied, through illustrate the coupling mechanism among thermal accumulation mechanism, hole-making damage and the tool wear, in addition, reveal the heat accumulation effect mechanism on tool life of high quality processing. Processing strategy that collaborative controlled quality and efficiency of composite/metal laminated structural parts sequential automatic hole-making, together with advanced method that adaptive controlled drilling temperature by combing low temperature and oil mist lubrication multi-energy is proposed to form new integrated hole-making technology of "Measurement-Processing-Monitoring" for composite/metal laminated structural parts, which will fulfill sequential hole-making experimental verification on typical aerospace composite/metal laminated structural parts. The research achievements are expected to preliminarily solve the aviation equipment development problem of rapid tool wear, frequent tool change, poor hole-making efficiency and prone to damage, etc. during sequential hole-making process of composite/metal laminated structural parts, which also provides critical generic technology support for our country in the manufacturing of core laminated parts.

本项目面向国家飞机工业中航空叠层材料零部件高质高效连续自动化制孔的迫切需求，针对其连续制孔过程中热累积效应诱发的刀具磨损快、换刀频繁、制孔效率低且制孔损伤加剧的问题，以连续制孔温度演变特性为研究对象，从连续制孔温度演变机制，以及制孔温度与损伤、刀具磨损的关联机制进行突破，首先开展叠层材料制孔温度-材料断裂行为-刀具磨损形式相关性研究，进而阐明热累积效应与制孔损伤及刀具磨损的耦合作用机理，揭示热累积作用对刀具保质加工寿命的影响机制，提出叠层结构件连续制孔质量和制孔效率协同控制的工艺策略，开发低温和油雾润滑多能量复合的制孔温度自适应调控加工新方法，形成叠层结构零部件的“测量-加工-监控”一体化制孔技术，在典型航空叠层结构件上完成连续制孔实验验证。研究成果有望初步解决企业航空装备研制中叠层结构件连续制孔中热累积效应诱发的一系列难题，为我国叠层结构核心零部件的制造提供关键共性技术支持。

航空零部件高质高效连续自动化制孔的工程化应用需求十分迫切。本项目围绕连续制孔过程中热累积效应诱发的刀具磨损快、换刀频繁、制孔效率低且制孔损伤加剧的问题，从连续制孔过程中温度演变规律，以及制孔温度与制孔损伤、刀具磨损之间的相互作用机制等方面进行突破。首先开展了连续制孔中温度梯度数据的在线测量方法研究，提出了引线和刀具基底一体化的设计思想，进而提出了“测温-制孔”于一体的刀具表面薄膜热电偶制作工艺，应用纳米涂层技术和陶瓷烧结技术进行引线和刀具基底集成制造，实现了在刀具表面特定位置和区域直接生长功能薄膜，保证了引线和薄膜连接的可靠性。在此基础上，基于Zigbee设计了可跟随旋转的温度信号无线传输装置，研制出智能测温刀具的原型，解决了连续制孔过程中旋转刀具瞬态温度无法原位感知的难题。基于应力不变量理论二次开发了适用于三维实体单元的复合材料各向异性材料本构，建立了虑及材料温变特性的三维钻削热力耦合有限元模型，通过将前一次钻削模拟产生的温度数据赋予下一次钻削模拟的预定义场，实现了连续制孔过程模拟，为揭示连续热累及作用对制孔损伤的形成和扩展机制奠定了基础。针对连续制孔中刀具快速磨损换刀时机无法确定的关键问题，采用所研制的测温制孔一体化刀具研究了不同制孔温度下刀具切削性能衰变规律，以及刀具磨损与制孔温度、制孔损伤之间的关联关系。通过将制孔温度与制孔损伤数据以时间为中心进行逐点匹配，建立了基于人工神经网络的制孔温度梯度与制孔损伤程度之间的映射模型。根据损伤容限指标的控制条件，将刀具保质加工寿命引入三者之间的关系模型，结合机器学习算法建立了以连续制孔温度数据驱动的刀具保质加工寿命预测模型，为可延长刀具保质加工寿命制孔温度范围的确定提供了数据支撑。研究成果的应用将为实现先进航空零部件高质、高效连续自动化制孔提供理论和方法支持，对提升我国航空工业制造水平和能力具有重要意义。