基于碳纤维复合材料切削加工回弹效应的刀具磨损机制与工艺控制研究

Carbon fiber reinforced polymer (CFRP) composites are widely used in aerospace due to its excellent comprehensive performance. However, as a typical material that is difficult to process, wear of flank face is an intractable problem for processing of carbon fiber-reinforced polymer (CFRP), and the current theories and methods could not make an in-depth analysis for the effect of rebound mechanism on the flank face. Therefore, in this project, the rebound deformation of CFRP with different layer angle in the flank face area is taken as the research object. The rebound mechanism under different process conditions, the correlation mechanism between the rebound and the cutting temperature, the tool wear are taken as the research focus. Firstly, the correlation among the bending deformation state of carbon fiber- changes in material properties- tool friction is researched. Then couple mechanism between the rebound effect and the cutting heat, the tool wear is described. The mutagenic mechanism of the contact between the tool and the.workpiece of the flank face for the cutting force, the cutting temperature and the rebound is proposed, and it provides theoretical and technical support for the realization of high efficiency, high precision and low cost machining of carbon fiber composites, which is of great academic significance and industrial application value for improving the level of CFRP processing in China.

碳纤维增强树脂基复合材料(CFRP)因其良好的综合性能在航空航天领域得到了广泛的应用。然而，作为典型的难加工材料，后刀面磨损是CFRP加工无法回避的难题，现有理论和方法缺乏对后刀面区域变形回弹机制的深入分析。为此，本项目以刀具后刀面位置不同铺层角度碳纤维复合材料变形回弹特性为研究对象，从不同工艺条件下回弹的形成机制，以及回弹量与温度、刀具磨损的关联机制进行突破，首先开展碳纤维弯曲变形状态-材料组织性能变化-刀具摩擦形式相关性研究，进而阐述回弹效应与后刀面切削热量及刀具磨损的耦合作用机理，揭示后刀面刀具-工件接触形态对切削力、切削温度及材料变形回弹诱变机制，提出针对后刀面区域变形回弹效应的碳纤维复合材料加工工艺优化控制策略，为实现碳纤维复合材料高效、高精度、低成本切削加工提供理论和方法支持，对于提升我国碳纤维复合材料加工水平具有重要的学术意义和产业化应用价值。

随着航空制造技术的进步与发展，碳纤维增强树脂基复合材料(CFRP)因其良好的综合性能得到了广泛的应用，复合材料用量已成为衡量飞机先进性的重要标志之一。CFRP构件与其他航空结构件装配时，大都需要钻削、铣削等后续机械加工方式，以满足装配的精度要求，其中钻削占后续机械加工总量的50%以上。然而，作为典型的难加工材料，后刀面磨损是CFRP加工无法回避的难题，现有理论和方法并未实现对后刀面区域变形回弹机制的深入分析。为此，本项目以刀具后刀面位置不同铺层角度碳纤维复合材料变形回弹特性为研究对象，从不同工艺条件下回弹的形成机制，以及回弹量与温度、刀具磨损的关联机制进行突破，首先开展碳纤维弯曲变形状态-材料组织性能变化-刀具摩擦形式相关性研究，进而阐述回弹效应与后刀面切削热量及刀具磨损的耦合作用机理，揭示后刀面刀具工件接触形态对切削力、切削温度及材料变形回弹诱变机制，提出针对后刀面区域变形回弹效应的碳纤维复合材料加工工艺优化控制策略，为实现碳纤维复合材料高效、高精度、低成本切削加工提供理论和方法支持。. 该项研究可有效补充复合材料高效加工工艺理论体系，并广泛推广于航空、航海等相关复材应用产业。目前，研究成果已经成功应用于多个相关项目，有效提升了产品制孔质量与制孔效率，得到了相应用户单位的一致好评。