基于高阶振形优化的CFRP低频振动辅助钻削研究

Research on Low Frequency Vibration-assisted Drilling of CFRP Based on High-order Vibration Shape Optimization

  • 摘要: 碳纤维增强树脂基复合材料(Carbon Fiber Reinforced Polymer,CFRP)广泛应用于航空航天领域,制孔工艺是零部件装配的关键环节。由于碳纤维的高磨蚀性,钻削加工过程中刀具易磨损,制孔质量难以保证。低频振动辅助钻削通过刀具与工件的周期性接触分离,可减少摩擦并延长刀具寿命。但传统的正弦振动无法灵活调整接触时间,本文提出通过将单一正弦波形改变为高阶振形,以优化占空比为目标(M1~M4,占空比分别为0.35、0.39、0.419、0.452),减少刀具与工件接触时间,进一步减小刀具磨损。试验表明,不同振形在前10个孔的轴向力和扭矩接近,第20个孔时高阶振形M1轴向力和扭矩比常规振形M0(占空比为0.419)分别降低了9.92%和11.99%。刀具磨损以磨粒磨损为主,并伴有切屑粘附,M1振形较M0振形后刀面磨损量降低43.82%,且孔径和粗糙度值变化范围更小、出口分层因子降低了10.6%。综上,减小占空比可以降低钻削力、刀具磨损和提高制孔质量,优选出的高阶振形M1能更有效抑制刀具磨损和加工缺陷。研究结果为CFRP的低频振动辅助钻削工艺提供了高阶振形优选的参考依据。

     

    Abstract: Carbon fiber reinforced polymer (CFRP) is widely used in the aerospace industry, and drilling process is a critical process in component assembly. Due to the high abrasiveness of carbon fibers, tool experiences rapid wear during drilling process, compromising hole quality. Low frequency vibration-assisted drilling can reduce friction and extend tool life by enabling periodic contact and separation between the tool and workpiece. However, conventional sinusoidal vibration lacks flexibility in adjusting contact duration. This paper proposes replacing the single sinusoidal waveform with higher-order shapes to optimize duty cycle (M1~M4 with duty cycles of 0.35, 0.39, 0.419, and 0.452 respectively), aiming to reduce tool-workpiece contact duration and thereby mitigate tool wear. The experimental results indicate that the thrust forces and torques of different vibration shapes are similar for the first 10 holes. When reaching the 20th hole, the higher-order vibration shape M1 demonstrates reductions in thrust force and torque by 9.92% and 11.99% respectively compared to the conventional vibration shape M0 (with a duty cycle of 0.419). Tool wear is primarily dominated by abrasive wear, accompanied by chip adhesion. Compared to the M0 vibration shape, the M1 vibration shape reduces flank wear by 43.82%, exhibits a smaller hole diameter and roughness value variation range, and decreases the exit delamination factor by 10.6%. In summary, reducing the duty cycle can reduce drilling force and tool wear while improving hole quality. The optimized high-order vibration shape M1 demonstrates enhanced effectiveness in suppressing tool wear and machining defects. The research results provide a reference for the optimization of high-order vibration shapes in the low frequency vibration-assisted drilling process of CFRP.

     

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