Calculation of the heat distribution ratio of tool-chip-workpiece and prediction of cutting temperature during the peripheral milling process of carbon fiber reinforced thermoplastic resin matrix composites
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摘要: 碳纤维增强热塑性树脂基复合材料(简称“热塑性复材”)对温度变化敏感。针对碳纤维/聚醚醚酮(CF/PEEK)热塑性复材周铣加工过程，建立了包括各向异性材料塑性变形与刀-工-屑多面摩擦作用的复合热源模型，求解了以不同纤维方向切削热塑性复材时刀-工-屑的切削热量分配比例，最终构建了热塑性复材周铣温度预测模型，并由此分析了纤维方向、切削速度、进给量等工艺参数的影响。经实验验证，模型平均预测误差低于11.5%。结果表明：大角度切削时，流入工件的热量比例更高，导致铣削温度更高。随切削速度的增大，铣削温度先上升后下降，切削速度临界值在100 m/min附近；而随着进给量增加，铣削温度总体呈下降趋势，当进给量由0.01 mm/r增大到0.1 mm/r时，铣削温度下降40%以上。Abstract: Carbon fiber reinforced thermoplastic resin matrix composites (CFRTP) are sensitive to temperature change. A composite heat source model for the peripheral milling process of carbon fiber (CF)/poly(ether-ether-ketone) (PEEK) thermoplastic composites was established, which included the plastic deformation of anisotropic materials and the multi-faceted friction from tool-workpiece and tool-chip. The cutting heat distribution ratio of tool-chip-workpiece was solved when cutting thermoplastic composites in different fiber orientations. Finally, a prediction model for the peripheral milling temperature of thermoplastic composite materials was constructed, and the effects of process parameters such as fiber orientations, cutting speed and feed rate were analyzed. Through experimental verification, the average prediction error of the model is less than 11.5%. The results show that a higher proportion of heat flows into the workpiece when performing machining with a large cutting angle, resulting in higher milling temperatures. With the increase of cutting speed, the milling temperature first increases and then decreases, and the critical value is around 100 m/min. As the feed rate increases, the overall milling temperature shows a downward trend. When the feed rate increases from 0.01 to 0.1 mm/r, the milling temperature decreases by more than 40%.
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图 1 碳纤维增强热塑性树脂基复合材料(CFRTP)周铣温度计算流程示意图
Figure 1. Schematic diagram of carbonfiber reinforced thermoplastic resin matrix composites (CFRTP) milling temperature calculation process
图 2 CFRTP加工时产热示意图
Figure 2. Schematic diagram of heat source during CFRTP processing
v—Cutting speed (feed speed)
图 3 CFRTP加工时传热机制示意图
Figure 3. Schematic diagram of heat transfer mechanism during CFRTP processing
qrake—Heat flux density of friction heat source on rake face; qplastic—Heat flux density of plastic deformation heat source; qflank—Heat flux density of friction heat source on flank face; R1—Distribution ratio of plastic deformation heat transmitted to chip; R2—Proportion of heat generated by friction between the tool and the chips transmitted to chip distribution; R3—Proportion of heat generated by friction between the tool and the workpiece transmitted to the workpiece distribution; Rchip—Heat distribution ratio of incoming chips; Rtool—Heat distribution ratio of incoming the tool; RCFRTP—Heat distribution ratio of incoming the workpiece
图 5 刀具与工件接触长度示意图
Figure 5. Schematic diagram of contact length between cutting tool and workpiece
lc1—Contact length between chips and rake face; lc2—Contact length between the corner and the workpiece; lc3—Contact length between flank face and machined surface
图 6 CFRTP周铣传热示意图
Figure 6. Heat transfer diagram of CFRTP peripheral milling
N—Tool speed; ωc—Angle of the tool turning when cutting the workpiece; ω—Angle of a point in the workpiece relative to the origin of the coordinate; dω—Small increment of tool turning angle; X, Z—Distance from a point on the workpiece to the two axes respectively; R—Radius of milling cutter
图 7 CFRTP铣削实验示意图
Figure 7. Schematic diagram of CFRTP milling experiment
PC—Industrial personal computer
图 11 红外成像仪下周铣装置示意图
Figure 11. Schematic diagram of infrared imager peripheral milling device
图 12 纤维方向角对工件温度((a)~(c))和热分配比例系数((d)~(f))的影响：((a), (d)) v=100 m/min，fz=0.05 mm/r；((b), (e)) v=200 m/min，fz=0.05 mm/r；((c), (f)) v=100 m/min，fz=0.1 mm/r
Figure 12. Influence of fiber orientation angle on workpiece temperature ((a)-(c)) and heat partition ratio coefficient ((d)-(f)): ((a), (d)) v=100 m/min, fz=0.05 mm/r; ((b), (e)) v=200 m/min, fz=0.05 mm/r; ((c), (f)) v=100 m/min, fz=0.1 mm/r
图 13 切削速度对工件温度((a), (b))和热分配比例系数((c), (d))的影响(fz=0.05 mm/r)
Figure 13. Influence of cutting speed on temperature ((a), (b)) and heat partition ratio coefficient ((c), (d)) of workpiece (fz=0.05 mm/r)
图 14 进给量对工件温度的影响：(a) 0°；(b) 90°
Figure 14. Influence of feed rate on temperature of workpiece: (a) 0°; (b) 90°
表 1 CFRTP材料属性
Table 1. Properties of CFRTP
Parameter Value Longitudinal tensile strength/MPa 2070 Transverse compressive strength/MPa 102 Longitudinal Young's modulus/GPa 127 Transverse Young's modulus/GPa 10.3 Poisson's ratio 0.3 Glass transition temperature of resin Tg/℃ 143 
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表 2 刀具参数和加工参数
Table 2. Tool parameters and machining parameters
Parameter Value Tool diameter D/mm 10 Main cutting edge rake angle γ0/(°) 5 Main cutting edge clearance angle α/(°)
Number of main cutting edges
Coating3
2
Black nanometerCutting speed v/(m·min−1) 25, 50, 100, 150, 200 Feed per revolution fz/(mm·r−1) 0.01, 0.025, 0.05, 0.075, 0.1 Radial cutting depth a'c/mm
Milling mode0.3
Climb milling
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