基于表面粗糙度和反射率多目标优化的6061铝合金超精密车削工艺研究  

Ultra-precision Turning Process of 6061 Aluminum Alloy Based on Multi-objective Optimization of Surface Roughness and Reflectivity

作　　者：王光余 靳刚[1,2] 李占杰 谭辉 詹奇云 林怀鑫 王晓然 WANG Guangyu;JIN Gang;LI Zhanjie;TAN Hui;ZHAN Qiyun;LIN Huaixin;WANG Xiaoran(School of Mechanical Engineering,Tianjin University of Technology and Education,Tianjin 300222,China;Tianjin Key Laboratory of High Speed Cutting and Precision Processing,Tianjin 300222,China;Tianjin Aerospace Institute of Electrical and Mechanical Equipment,Tianjin 300301,China)

机构地区：[1]天津职业技术师范大学机械工程学院,天津300222 [2]天津市高速切削与精密加工重点实验室,天津300222 [3]天津航天机电设备研究所,天津300301

出　　处：《表面技术》2024年第12期193-206,共14页Surface Technology

基　　金：国家自然科学基金面上项目(51875487);天津市自然科学基金重点项目(22JCZDJC00740)。

摘　　要：目的探究工艺参数对6061铝合金滚压件超精密车削性能的影响,对工件超精密车削加工表面粗糙度和表面光学反射率进行协同优化研究。方法首先,对6061铝合金材料表面进行单向超声振动滚压以提高工件表面质量。其次,设计了四因素四水平的超精密车削正交试验,研究了切削工艺参数(主轴转速、进给速度、背吃刀量、刀尖半径)对6061铝合金滚压件表面粗糙度及表面光学反射率的影响规律。最后,采用灰色关联分析方法,将多个工艺目标参数优化问题转化为单目标的灰色关联度优化问题,通过超精密车削试验对优化结果进行验证。结果主轴转速对表面粗糙度Ra和Sa的影响最显著,其次是刀尖半径和背吃刀量,进给速度的影响最小;工艺参数对可见光波段和中红外光波段反射率的影响程度与表面粗糙度一致,各参数按对近红外光波段反射率影响程度由大到小的顺序依次为背吃刀量、刀尖半径、进给速度、主轴转速;通过灰色关联分析获得优化工艺参数组合为主轴转速3000 r/min、进给速度10 mm/min、背吃刀量5μm、刀尖半径0.5 mm,此时对应的表面粗糙度R_(a)和S_(a)分别为2.162 nm和7.855 nm,可见光、近红外光、中红外光波段反射率分别为88.892%、88.893%、97.788%。结论通过优化结果能够有效降低表面粗糙度、提升表面光学反射率,对制造高水平金属反射镜具有十分重要的现实意义和研究价值。Single point diamond turning(SPDT)is currently an important technology in the field of ultra-precision machining,mostly used in the manufacture of high-precision optical components.The 6061 aluminum alloy combined with SPDT technology,can be directly used for the optical system to create a high level of metal mirrors.Since the surface machining accuracy and surface optical properties in single-point diamond ultra-precision turning technology are affected by many factors,it is necessary to analyze the effect of process parameters on the surface roughness and optical properties of the material after ultra-precision turning.The work aims to explore the effect of process parameters on the ultra-precision turning performance of rolled 6061 aluminum alloy parts,and carry out a synergistic optimization study on the surface roughness and surface optical reflectivity of the workpiece ultra-precision turning process.First of all,the surface of 6061 aluminum alloy material was subject to one-way ultrasonic vibration rolling to improve the surface quality of the workpiece.The surface of the material was subject to the joint effect of the spindle speed of the rolling head,feed speed and high-frequency ultrasonic impact amplitude,and the preparation of test pieces by ultrasonic rolling before ultra-precision turning laid a good foundation for the subsequent ultra-precision turning test.Then,a 4-factor,4-level orthogonal test of ultra-precision turning was designed to investigate the effect of cutting process parameters(spindle speed,feed rate,back-eating amount,and tip radius)on the surface roughness and surface optical reflectivity of rolled 6061 aluminum alloy parts.In addition,the interconnection between surface roughness and surface reflectivity was explored.Finally,the grey correlation analysis method was adopted to transform multiple process objective parameter optimization problems into single-objective grey correlation degree optimization problems,and the optimization results were verified through the ultra-precision t

关 键 词：单点金刚石车削 6061铝合金 正交试验 表面粗糙度 表面光学反射率 灰色关联分析 

分 类 号：TG519.3[机械工程—精密仪器及机械]