Study on Technology of Ultrasonic Vibration Drilling of CFRP with Low Damage
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摘要: 为了研究碳纤维复合材料超声振动加工机理，本文提出了直角切削三维细观有限元方法并开展了手持式超声制孔实验。首先，基于直角-斜角切削转换关系构建热力耦合有限元模型进行普通和超声振动直角切削仿真，实现对制孔损伤如纤维断裂、基体破坏及纤维-基体界面脱粘的预测，研究了振动频率如幅值和频率对切削力的影响规律；然后，基于四组特殊纤维方向角的有限元仿真结果，进行了能量分析以量化不同能量耗散机制在普通和超声振动直角切削下的百分比，结合切屑形貌对比，针对为何超声振动能减小钻削力及提高制孔质量进行了剖析。最后，基于仿真获取的振动参数影响规律开展了普通钻削及超声振动钻削的对比实验，并对钻削力与亚表面损伤情况进行了对比。结果表明，基于有限元仿真获取合理的振动参数，有助于实际加工应用中减小钻削力及提高加工质量。Abstract: This paper proposes a finite element (FE) method for the orthogonal cutting simulation, and ultrasonic drilling experiments with hand-held ultrasonic vibration drilling system is carried out so as to study the mechanism of material removal in machining of composite materials. Firstly, based on the orthogonal to oblique cutting transformation, a thermo-mechanical FE model was established to simulate the conventional drilling (CD) and ultrasonic vibration drilling (UVD) processes. Drilling-induced damage such as fiber fracture, matrix cracking and fiber-matrix interfacial debonding were predicted. The effect of the vibration amplitude and frequency on the cutting forces was studied. Then, based on the FE simulation results at four specific fiber orientations, energy balance analysis is carried out to quantify the dominating energy dissipating mechanisms during CD and UVD, respectively. Combining with the comparison of chip formation, the reason which ultrasonic vibration technology can reduce drilling forces and improve surface quality is analyzed. Finally, experiments with various process parameters were performed, and the drilling thrust forces and sub-surface damage were compared. Results show that the optimized vibration parameters obtained by the FE approach can contribute to reducing drilling forces and improving machining quality in the practical machining processes.
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Key words:
- composite /
- ultrasonic vibration drilling /
- finite element method /
- energy analysis
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表 1 制孔工艺参数
参数 数值 CFRP工件 工件尺寸(mm×mm×mm) 50×40×6 制孔工艺
参数进给速度v/(μm·r-1)
转速n/(r·min-1)
刀具直径D/mm30, 40
3 000
Ø3.26, Ø5超声
振动参数频率f/kHz
幅度a/μm20
3
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