基于斜角切削的CFRP螺旋铣孔微观仿真分析  

Microscopic Simulation Analysis of CFRP Helical Milling Based on Oblique Cutting

作　　者：周兰 王云龙 安国升[2] 朱瑞彪 李光奇 马蓉 ZHOU Lan;WANG Yunlong;AN Guosheng;ZHU Ruibiao;LI Guangqi;MA Rong(School of Mechanical and Electronical Engineering,Lanzhou University of Technology,Lanzhou 730050,China;State Key Laboratory of Advanced Processing and Recycling of Nonferrous Metals,Lanzhou University of Technology,Lanzhou 730050,China;Guangxi Liugong Group Co.,Ltd.,Liuzhou 545007,China)

机构地区：[1]兰州理工大学机电工程学院,兰州730050 [2]兰州理工大学省部共建有色金属先进加工与再利用国家重点实验室,兰州730050 [3]广西柳工集团有限公司,柳州545007

出　　处：《航空制造技术》2024年第21期14-26,共13页Aeronautical Manufacturing Technology

基　　金：国家自然科学基金(52265049);甘肃省青年博士基金(2021QB-043);甘肃省科技重大专项(22ZD6GA008)。

摘　　要：针对碳纤维增强复合材料(Carbon fiber reinforced polymer,CFRP)螺旋铣孔中铣刀侧刃瞬态铣削体现出的复杂斜角切削特性,为深入揭示不同纤维方向角(θ)的CFRP螺旋铣孔成屑机制,构建基体相、纤维相与界面相CFRP斜角切削有限元模型。分析0°、45°、90°与135°的CFRP纤维失效机制,探究刀具倾斜角(i)与切屑尺寸间的关系,揭示残余应力随加工参数的变化规律,同时阐明加工参数与θ对切削力的影响。结果表明:纤维在θ为0°与135°时发生弯曲失效,45°时发生剪切失效,90°时弯曲与剪切失效均存在;θ为0°、45°、90°的切屑尺寸均与i呈正相关,θ为135°的切屑尺寸与i无相关性;残余应力与切削速度呈正相关,与切削深度无相关性;θ为90°与0°时切削力分别呈最大值与最小值,当0°<θ<90°时,切削力呈增大趋势,90°<θ<135°时,切削力呈降低趋势;切削力与切削速度、深度均呈正相关,不同切削速度、深度的切削力仿真值与试验值最大误差不超过11%与9%,能够对CFRP螺旋铣孔切削力进行有效预测。In order to deeply reveal the chip formation mechanism of carbon fiber reinforced polymer(CFRP)helical milling at different fiber orientation angles(θ),for the complex oblique cutting characteristics reflected in the side edge milling process of CFRP helical milling,a microscopic finite element model of CFRP oblique cutting in matrix,fiber,and interfacial phases is constructed.The fiber failure mechanism of CFRP after machining atθof 0°,45°,90°,and 135°was analyzed.The relationship between tool oblique angle(i)and chip size was explored,and the change law of residual stress with machining parameters was revealed,at the same time,the influence of the machining parameters andθon the cutting force was elucidated.The results show that the fiber bending failure occurs atθof 0°and 135°,shear failure occurs at 45°,and both bending failure and shear failure exist at 90°;Chip size at 0°,45°and 90°are all positively correlated with i,and chip size at 135°is not correlated with i;Residual stress is positively correlated with cutting speed,not correlated with cutting depth;The cutting force shows the maximum value whenθ=90°and the minimum value whenθ=0°.When 0°<θ<90°,the cutting force tends to increase,when 90°<θ<135°,the cutting force tends to decrease.It can be seen that the cutting force is positively correlated with the cutting speed and depth,and the maximum error between the simulated and experimental cutting force values for different cutting speed and cutting depth is no more than 11%and 9%,which can predict cutting forces in CFRP helical milling.

关 键 词：螺旋铣孔 碳纤维增强复合材料(CFRP) 斜角切削 纤维方向角 有限元模型 

分 类 号：TB332[一般工业技术—材料科学与工程] TB115[理学—数学]