拟间歇振动辅助转摆车削复杂光学曲面元件的界面特性及机理研究

The quasi-intermittent vibration assisted swing turning inherits the characteristics of intermittent cutting of elliptical vibration cutting, and can solve the residual height problem between adjacent trajectories in the elliptical vibration cutting process. In recent years, the applicant and his research group has developed a quasi-intermittent vibration-assisted swinging cutting equipment,but the mechanism of the complex surface processing of optical difficult-to-cut materials is still unclear. Therefore, this project proposes the tool-turning during the intermittent vibration-assisted turning process. The active adjustment method of the pendulum axis precisely controls the tool turning to obtain the best cutting effect. By characterizing the tool-chip interface contact characteristics under high-frequency vibration conditions, the friction mechanism model of the tool-chip interface is established, and the quasi-intermittent vibration assisted turning is revealed. The friction lubrication effect of the turning method and the anti-wear mechanism of the tool; the minimum cutting thickness and the critical depth of cut model for the quasi-intermittent vibration assisted turning are established, and the low damage high efficiency removal mechanism of the optically difficult material is studied; The influence of process parameters on the processing performance during the cutting process;This project will provide a key theoretical basis and technical basis for the cutting of optically difficult-to-cut materials, which is of great significance for the promoting the breakthrough in the field of engineering applications.

拟间歇振动辅助转摆切削继承了椭圆振动切削间歇性切削的特点，能够解决椭圆振动切削过程中相邻轨迹间残留高度问题。项目申请人近年来针对拟间歇振动辅助转摆切削开展研究，但是其在光学难加工材料复杂面型加工的机理尚不明确，因此，本项目提出拟间歇振动辅助转摆切削过程中对刀具转摆轴主动校正方法，精准控制刀具转摆以获得最佳切削效果；通过表征高频振动条件下的刀具-切屑界面接触特性，建立刀具-切屑界面的摩擦机制模型，揭示拟间歇振动辅助转摆车削方法的摩擦润滑效应和刀具的抗磨损机理；建立拟间歇振动辅助转摆切削最小切削厚度、临界切深模型，研究光学难加工材料的低损伤高效率去除机制；研究拟间歇振动辅助转摆切削过程中工艺参数对加工性能影响规律；本项目研究将为光学难加工材料切削加工提供关键的理论基础和技术基础，对于推动复杂面型光学元件在诸多受关注领域中获得突破性的工程应用具有重要的意义。

椭圆振动辅助切削技术具有的摩擦力逆转和间歇性切削特性，能够延长刀具使用寿命，改善难加工材料在传统制造中存在的缺陷，但其存在相邻轨迹间刀具残留高度无法消除、系统控制困难等问题，因此本项目提出了拟间歇振动辅助转摆车削新技术用于加工光学难加工材料的复杂面型，以期进一步提高其加工效率和加工质量。.项目结合拟间歇振动辅助转摆车削技术的前期研究，进一步优化了拟间歇振动辅助转摆车削装置设计，运用运动学、柔度和动力学理论对研制的装置进行了理论模型建立与分析、采用实验对搭建装置的工作行程、分辨率、闭环跟踪和串扰等各项性能进行测试，为搭建的装置可靠性提供了依据；利用hermite样条插值定理，提出了一种与拟间歇振动辅助转摆车削技术匹配的刀具路径生成策略；采用建模分析的方法，研究了切削工艺参数-工件界面接触模型，分析了切削过程中工艺参数对切削力的影响和刀具-切屑之间的摩擦特性，为其机理研究提供了理论基础；采用了变切深刻划的实验方法，研究不同加工参数对临界未变形切屑厚度的影响规律，分析了其切削机理；采用端面切削实验和曲面切削实验对拟间歇振动辅助转摆车削技术的加工性能进行了验证，证实了其确实有消除残留高度的效果，进一步的提高了光学难加工材料的加工效率和加工质量。.上述研究结果对于拟间歇振动辅助转摆车削技术的推广应用有较好的促进作用，同时进一步丰富了椭圆振动切削理论和技术，对提升我国先进制造技术水平，促进光学难加工材料在电子信息、航天航空等领域的应用发展，具有重要的科学意义和应用价值。