混联机器人UD-CFRP铣削过程切削力及加工质量分析

秦旭达; 张艳; 李皓; 李士鹏; 牛文铁; 尚帅

doi:10.13433/j.cnki.1003-8728.20190345

混联机器人UD-CFRP铣削过程切削力及加工质量分析

doi: 10.13433/j.cnki.1003-8728.20190345

天津大学机构理论与装备设计教育部重点实验室，天津　300350

基金项目: 国家科技重大专项（2017ZX04013001）、国家自然科学基金青年项目（51705358）及天津市自然科学基金项目（16JCZDJC38300）资助

详细信息

作者简介:
秦旭达（1973−），教授，博士，研究方向为飞机数字化装配技术和系统，难加工材料加工新技术，qxd@tju.edu.cn

通讯作者:
李皓，讲师，博士，haolitju@tju.edu.cn

中图分类号: TG156
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- 被引次数: 0
出版历程
- 收稿日期: 2019-05-29
- 网络出版日期: 2020-12-08
- 刊出日期: 2020-12-05

Analysis of Cutting Force and Quality for Hybrid Robot in UD-CFRP Milling

Key Laboratory of Mechanism Theory and Equipment Design of Ministry of Education, Tianjin University, Tianjin 300350, China

摘要

摘要: 随着碳纤维增强复合材料（Carbon fiber reinforced plastic, CFRP）在航空航天领域应用比例的增多，其切削加工也逐渐成为研究热点。基于TriMule混联机器人加工平台，通过螺旋立铣刀CFRP铣削实验，识别了不同切削条件下对应的切削力系数，发现CFRP铣削过程中的径向、切向切削力系数可以表示为纤维切削角的三角函数。结合不同切削参数的CFRP铣削实验对所提出的铣削力模型的准确性进行验证，分析了纤维切削角对CFRP铣槽加工质量的影响规律。在CFRP铣削加工中，毛刺按照其形成机理可以分为Ⅰ型和Ⅱ型两种，其中Ⅰ型毛刺由纤维在切削平面的弯曲变形引起，Ⅱ型毛刺由纤维在切削平面和垂直于切削平面的弯曲变形引起。试验结果表明，Ⅰ型毛刺长度随起始纤维切削角β_s的增大而减小，Ⅱ型毛刺长度随截止纤维切削角β_e的增大而增大。
- CFRP /
- 铣削力模型 /
- 纤维切削角 /
- 毛刺长度 /
- 加工表面质量
Abstract: With the increasing application of carbon fiber reinforced plastics (CFRP) in aircrafts, CFRP milling has become a research hotspot. A set of experiments in UD-CFRP milling for multiple helix tools has been carried out by using hybrid robot at different fiber angle, and the cutting force coefficients in tangential and radical directions are calculated. The results demonstrate that cutting force coefficients can be presented as a sine function of fiber cutting angle. The force model is capable of predicting cutting forces in the milling of CFRP with different process parameters. The effects of the fiber cutting angle on the milling surface quality of CFRP have been investigated. In the milling of CFRP, there are two different types of fiber burrs according to different deflection mechanisms of fiber, type Ⅰ and type Ⅱ. Type Ⅰ fiber burrs are related to the bending of fiber in the laminate plane, type Ⅱ related to the bending of fiber in the laminate plane as well as perpendicular to the laminate plane. The results show that the length of type Ⅰ fiber burrs decreases with the increasing of initial fiber cutting angle β_s, the length of type Ⅱ fiber burrs increases with increasing of final fiber cutting angle β_e.
- CFRP /
- model for cutting force /
- cutting angle of Fiber /
- length of burr /
- surface quality

HTML全文

图 1 纤维切削角β随刀具转角Φ的变化规律(θ=0°)

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图 2 不同刀具转角处纤维切削角随纤维方向角的变化规律

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图 3 CFRP铣削过程示意图

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图 4 铣削加工试验现场图

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图 5 CFRP铣削实验方案

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图 6 不同纤维方向角UD-CFRP铣边加工切削力系数随刀具转角的变化规律 (n=3500 r/min, f=0.015 mm/齿, a_w=2.5 mm)

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图 7 UD-CFRP铣边加工切削力系数拟合结果与试验结果对比

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图 8 UD-CFRP铣边加工切削力测量结果与理论结果对比（n = 3 500 r/min, f = 0.015 mm/齿, a_w = 2.5 mm)

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图 9 CFRP铣槽过程切削力仿真结果与实测结果对比图（n = 3 500 r/min, a_w = 5 mm, θ= 450）

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图 10 CFRP铣槽加工毛刺分布图(n=3500 r/min，f=0.015 mm/齿，θ=75°)

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图 11 不同纤维方向UD-CFRP铣槽加工毛刺分布 (n=3500 r/min，f=0.015 mm/齿)

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图 12 不同纤维方向CFRP铣槽加工Ⅰ型毛刺长度、切削力系数以及表面形貌随起始纤维切削角β_s的变化规律图

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图 13 不同纤维方向CFRP铣槽加工Ⅱ型毛刺长度、表面形貌随截止纤维切削角β_e的变化规律图

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表 1 CFRP铣边实验加工参数

纤维方向角/ (°)	主轴转速n/ (r·min⁻¹)	每齿进给量f / (mm·齿⁻¹)	进给速度/ (mm·min⁻¹)	轴向切削深度a_p/ mm	切削宽度a_w/ mm
0~165	3500	0.015	210	1	2.5

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表 2 不同纤维方向CFRP铣边加工纤维切削角以及对应的铣削力系数辨识结果（Φ=45°）

θ/(°)	β/(°)	K_t/(N·mm⁻²)	K_r/(N·mm⁻²)
0	45	421.9	1360
15	30	1422	4581
30	15	2356	7594
45	0	2689	8665
60	165	3468	11800
75	150	4024	12970
90	135	4323	13930
105	120	3347	10380
120	105	2646	8203
135	90	1831	5676
150	75	912	2827
165	60	689.4	2137

下载: 导出CSV

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