振动辅助车铣加工仿生表面关键技术及机理

Typical biological surfaces are selected based on specific industrial application background, their macroscopic characteristics and microstructures are extracted to establish mathematical models of bionic surfaces by coupling, decomposition and rebuilding. Changing rules of solid, liquid, gas and their coupling bionic interfaces are studied systematically to construct predictive bionic surface mechanism models. Investigate the characteristics of non-smooth morphology to construct an evaluation system for bionic surfaces, considering the influence of vibration mode and parameters with machining parameters, to reveal the machinability of bionic surfaces and their surface textures. Analyze the kinematic and dynamic characteristics of vibration assisted turning and milling to reveal the formation mechanism of bionic surfaces and surface textures. The influence of inhomogeneous strain and dislocation to the shear deformation stress and the deformation energy is studied based on the distribution of deformation zone and stress field. The influence of material properties, metallographic, vibration and machining parameters to the friction and wear characteristics, vibration and noise reduction performance, microwave absorbing and heat dispersion functions of bionic surfaces are investigated. It will provide the basis for simulation, prediction and engineering application to establish a theory, characteristic optimization and combined machining technologies of bionic surfaces. Vibration assisted turning and milling will provide high efficiency and low cost solution for the machining of part area and large scale bionic surfaces in defense and military industry, aviation and aerospace industry, and biological engineering, etc.

基于应用背景选取典型生物表面，提取其宏观与微观形貌特征，通过耦合、分解与重构建立仿生表面数学模型。研究典型仿生表面的固、液、气耦合界面作用机理，建立其性能预测模型。构建典型仿生表面的非光滑形态评价体系，结合振动辅助方式与加工参数优化仿生表面及其织构加工策略。分析典型仿生表面的振动辅助车铣加工运动学及动力学特性，实现仿生表面加工与材料特性的最佳匹配，获得满足设计要求的仿生表面。基于加工变形区及其应力场分析非均匀应变、位错等对剪切变形应力和变形能的影响，研究材料特性、振动参数和加工工艺参数对切屑变形、加工区温度场以及仿生表面摩擦磨损、减振降阻、吸波消音、散热等性能的影响机制，建立仿生表面优化和振动辅助车铣加工技术体系，为仿生表面设计和工程应用奠定基础。振动辅助车铣加工仿生表面技术可以解决国防军工、航空航天、生物工程等领域的局部表面或大规模仿生表面高效率低成本加工问题，具有重要的理论和实际意义。

通过机械学科与生物学科相互交叉，制备仿生类表面形态与功能结构是当前表面织构加工研究领域的热点，具有重要的理论和实际意义。基于MATLAB计算机图像处理技术，对获得的鱼鳞状表面进行图像处理，并通过正弦函数对获得的特征参数进行曲线拟合。建立进给方向超声振动辅助铣削表面织构加工模型，构建具有普遍适用性的刀尖轨迹闭合区域函数，明确了进给方向超声振动辅助铣削加工出的织构表面为相互堆叠的鱼鳞状纹理表面。通过建立超声振动辅助车削加工表面微织构理论模型，分析了刀具几何参数、切削参数以及振幅对织构形貌和尺寸的影响。基于刀具切削刃刃形复映原理和切削干涉效应，通过空间坐标转换和布尔运算将刀具切削刃刃形复映到加工工件切削表面，实现了对超声振动辅助车铣加工表面的三维形貌仿真预测。分别搭建超声振动辅助铣削和车削微织构表面加工平台，系统研究了各工艺参数对表面织构成形的规律和影响。建立了进给方向超声振动辅助铣削加工力学模型，通过不同主轴转速、进给速度和超声振幅等参数下的超声振动辅助铣削加工实验，验证所建立的超声振动辅助铣削加工力学模型准确性和规律性。通过对超声振动辅助铣削过程进行仿真，分析了织构化表面成形加工过程中的应力、应变及切削温度等。对超声振动辅助车铣加工的织构化表面进行了系统的表面特性研究，奠定了仿生类织构化表面的应用基础：通过接触角实验，研究了进给方向超声振动辅助铣削加工的鱼鳞状表面暴露在空气中的抗氧化性和疏水性；对加工试样表面进行干摩擦和贫油摩擦性能实验，验证了鱼鳞状表面具有优良的干摩擦和贫油摩擦特性；通过表面流体仿真，分析了不同类型的微观织构对表面减阻效果的影响。