超精密飞刀铣削刀具磨损及工件表面特征创成的在线评估新方法研究

Aiming at many key problems existed in the research of online evaluation of tool wear and its effects on machined surface quality in ultra-precision raster milling (UPRM), this project proposed a novel online evaluation method for tool wear and its effects on machined surface quality based on cutting chip morphology with the main feature that who is realized based on the intermittent cutting mechanism of UPRM and the closed correlations between tool wear characteristics, chip morphology and machined surface topography. This project combines both theoretical research and experimental investigation, committed to the online evaluation of tool wear by using cutting chip morphology, committed to the online prediction of the machined surface topography and roughness under tool wear by using cutting chip morphology, committed to the error analysis and compensation in the identification of tool wear characteristics and their effects on machined surface quality. The study in this project contributes to the theoretical research and technology breakthrough in the micro-cutting mechanism and the chip formation under tool wear, contributes to the precise online identification of tool wear characteristics and their effects on machined surface quality in UPRM. The research in this project will provide theoretical and technical support in enhancing the cutting efficiency, reducing the cutting cost of UPRM and widening the application of UPRM on the fabrication of optical micro-structures.

针对超精密飞刀铣削中刀具磨损及工件表面特征创成在线评估研究工作中存在的诸多关键问题，本课题提出一种基于切屑形貌的刀具磨损及工件表面特征创成的在线评估新方法，其主要特征在于：根据超精密飞刀铣削的间断性切削机制以及刀具磨损特征、切屑形貌特征和工件表面形貌特征之间的几何关系，利用切屑形貌实现刀具磨损及工件表面特征创成的在线评估。本课题结合理论研究与实验分析，致力于实现基于切屑形貌的刀具磨损特征在线评估；致力于实现基于切屑形貌的工件表面形貌及粗糙度值在线预测；致力于实现刀具磨损特征及工件表面特征创成辨识过程中的误差分析与精度矫正。通过本课题的研究，有助于促进微切削机理和刀具磨损下切屑形成的理论研究和技术突破，实现超精密飞刀铣削中刀具磨损及工件表面特征创成的在线精确辨识。本课题的研究将为提高加工效率、降低加工成本以及拓展金刚石刀具在光学微结构加工中的应用范围提供理论与技术支撑。

本项目围绕超精密飞刀铣削刀具磨损特征及其与切屑形貌和加工表面特征之间的内在联系，深入研究了刀具微崩刃磨损及刀具稳态磨损情况下刀具磨损特征及加工表面特征创成的在线评估方法。研究了刀具崩刃磨损和稳态磨损下切屑形貌及加工表面特征，搭建了基于切屑形貌的刀具磨损及加工表面特征创成的在线辨识方法；研究了刀具磨损与工件模态振动之间的内在联系，实现基于工件一阶模态振动的刀具磨损在线评估方法；研究了刀具稳态磨损对刀具几何参数的影响，以及刀具几何参数改变对加工表面质量的影响；研究了超精密飞刀铣削表面高频震纹的产生机理及刀具磨损对震纹分布的影响规律，提出抑制高频震纹产生的方法。本项目提供了一种新式的刀具磨损及加工表面特征创成的表征方法，并为加工表面质量改善提供参考。本项目研究以第一标注成果发表论文11篇；参编Springer出版书籍章节1章；申请中国发明专利9项；培养博士后1人、硕士研究生4人；研究成果获得国家科技日报的报道。