微米级高温合金蜂窝芯超声磨削/铣削机理研究及缺陷抑制方法  

Ultrasonic Grinding/milling Mechanism and Defect Restraint Method for Micronscale Superalloy Honeycomb Cores

作　　者：王海航 张芷健 陈明 郭国强[2,3] 王晨光 明伟伟 安庆龙 WANG Haihang;ZHANG Zhijian;CHEN Ming;GUO Guoqiang;WANG Chenguang;MING Weiwei;AN Qinglong(State Key Laboratory of Mechanical System and Vibration,School of Mechanical Engineering,Shanghai Jiao Tong University,Shanghai 200240,China;Shanghai Spaceflight Precision Machinery Institute,Shanghai 201600,China;Shanghai Shenjian Precision Machinery Technology Co.,Ltd.,Shanghai 201600,China)

机构地区：[1]上海交通大学机械与动力工程学院机械系统与振动国家重点实验室,上海200240 [2]上海航天精密机械研究所,上海201600 [3]上海神剑精密机械科技有限公司,上海201600

出　　处：《上海航天(中英文)》2025年第1期38-47,共10页Aerospace Shanghai(Chinese&English)

基　　金：国家自然科学基金资助项目(52375455);上海市科技计划资助项目(23XD1433400)。

摘　　要：微米级高温合金蜂窝芯具有轻量化、耐高温、密封性好等优点,在新一代航空发动机与高超飞行器中作为关键件的核心材料。微米级高温合金蜂窝芯极其微小,面积仅为常规高温合金蜂窝芯的1/10,兼具高温合金与薄壁结构的难加工特性,导致微米级高温合金蜂窝芯在加工过程中,极易出现毛刺、芯格变形、撕裂等缺陷问题。针对以上问题,设计了微米级高温合金蜂窝芯超声辅助磨削与铣削加工工艺。根据侧面加工时工件与刀具的几何关系,探究了高温合金蜂窝芯单双壁的切入角。基于磨削/铣削实验,掲示了微米级高温合金蜂窝芯超声磨削/铣削机理与缺陷形成机理。研究结果表明:侧面加工时,单双蜂窝壁的切入角度分别为60°与0°。在相同加工条件下,相比于普通砂轮磨削,铣刀切削力较小,生成的毛刺长度也较小。超声振动益于裂纹扩展,使得磨削力下降,毛刺长度减小,芯格变形与撕裂缺陷减少。以上研究为微米级高温合金蜂窝芯高效低损伤加工提供了理论基础。Micron-scale superalloy honeycomb cores(MSSHCs)have the advantages such as light weight,high temperature resistance,and excellent sealing,and have been used as the core material of key components in new generation aero-engines and hypersonic aircrafts.An MSSHC is extremely small,with an area of only 1/10 of a common superalloy honeycomb core.Therefore,it has the difficult machining characteristics of superalloy and thin-wall structure at the same time.This makes MSSHCs extremely prone to the defects such as burrs,core deformation,and tearing during machining.To solve the above problems,the ultrasonic assisted machining technology for MSSHCs is designed.The cutting angles of single and double walls of MSSHCs are investigated according to the geometric relationship between the workpiece and tool during side machining.Based on the grinding/milling experiment,the mechanisms of ultrasonic grinding/milling of MSSHCs and defect formation are revealed.The results show that the cutting angles of single and double honeycomb walls are 60°and 0°,respectively.Under the same machining conditions,compared with the grinding wheel,the designed milling cutter has smaller cutting force and shorter burr length.Ultrasonic vibration is beneficial to crack propagation,reducing the grinding force,burr length,core deformation,and tearing defects.The above investigations provide a theoretical basis for the high efficiency and low damage machining of MSSHCs.

关 键 词：高温合金 蜂窝芯 超声磨削 铣削 加工缺陷 

分 类 号：TG54[金属学及工艺—金属切削加工及机床]