碳化硅增强铝基复合材料去除机理及损伤消减策略

In the field of aeronautics and astronautics, high volume fraction SiCp/Al composite components have obvious characteristics of heterogeneity, imperfect interface and performance distortion between composition phases. It’s easily brought on difficulties and challenges such as damages, poor surface quality and serious wear of tools. The basic research of processing technology about SiCp/Al composite will be conducted to reveal the removal mechanism in the process of cutting. A mathematical models will be established considering about material composition phase’s performance distortion, SiC's volume fraction and non-ideal interface structure features. The mechanism of surface formation and damage formation can be illuminated by the model. The cutting principle for low damage cutting assisted by ultrasonic vibration and the high performance tools will be developed. A new process is put forward on the basis of multi-energy compound including ultra-low temperature, ultrasonic vibration assistance and cutting (temperature energy+ sound energy+ force energy). A new processing technology of high quality and efficient for SiCp/Al composites is formed which breaks the limitations of traditional processing. This work will provide theoretical foundation and technical support for precise and high quality processing of China's major engineering key equipment and high performance composite material components.

面向航空航天中高体积分数SiCp/Al复合材料构件，针对其具有明显的非均质、非理想界面和组成相性能畸变等特征，以及机械加工中所面临的极易产生损伤、表面质量差和刀具磨损严重等难题与挑战，开展SiCp/Al复合材料加工技术基础研究，揭示加工过程中材料去除机理，建立虑及材料组成相性能畸变、SiC体积分数与非理想界面结构特征的材料切削数学模型，阐明材料表面创成与损伤形成机制，探索超声振动辅助微刃低损伤切削原理，研制高性能专用工具，提出基于超低温、超声振动辅助和切削多能量场（温度场+声场+力场）复合的加工策略，突破传统加工技术局限，形成SiCp/Al复合材料高质高效加工新技术，为我国重大工程关键装备高性能复合材料构件的精确高质量加工提供理论基础和技术支持。

SiCp/Al复合材料由于优异的力学性能成为制造航空航天零部件的理想材料。项目针对SiCp/Al复合材料难加工特点，系统研究了材料去除机理、宏/细观形态演变规律、损伤形成机制、高表面完整性切削原理以及多能场复合加工工艺等方面内容，得出主要结论如下：.（1）研究了刀具对不同体积分数SiCp/Al复合材料去除特点，建立了体元直角切削力学模型和SiC颗粒与Al基间非理想界面的应力分布模型。随着增强相SiC颗粒和体积分数的增大，表面存在的凹坑深度和Al基体涂覆现象越大。.（2）研究了增强相SiC颗粒对刀具反切削作用，建立了传统加工和超声辅助加工刀具磨损模型，分析了切削力、热对表面质量的影响规律。研究表明超声振动的施加可以有效减少刀具的崩裂破损，选择合理的超声振幅和加工参数，可以有效提高表面质量。.（3）考虑增强相SiC颗粒的大小、形状和体积分数，基于ABAQUS GUI二次开发功能，开发了参数化建模系统软件。研制了螺旋铣磨螺纹加工刀具，与传统商用刀具相比具有更好的切削性能。分析了加工过成中切削力、切削热变化规律及对加工质量的影响。.（4）基于多能场复合作用建立了钻削和铣削模型，匹配了超声振动参数。相比于传统加工超低温可以改善SiCp/Al复合材料内部铝合金基体的性质，降低其塑性和韧性，增加脆性，缓解加工过程中Al基体的撕裂缺陷，超低温辅助振动加工后材料表面的Sq值显著低于普通加工后表面的Sq值，超低温辅助振动加工后的表面损伤更小。研究结果对提高航空航天零部件的产品质量和成品率提供了技术支持。.