碳纤维增强复合材料/轻合金叠层结构件制孔切削力建模研究进展

Research progress of cutting force modeling for drilling carbon fiber reinforced plastics/light alloy laminated structure parts

  • 摘要: 碳纤维增强复合材料/轻合金叠层结构件因具有高比强度、高比模量、高断裂韧性等优势,目前已成为航空航天领域关键承力结构件的首选。为确保整体结构件的加工效率与制孔质量,迫切需求针对叠层结构件开展一体化制孔加工。但是,碳纤维增强复合材料、轻金属及其二者的叠层界面存在非连续、不均质、各向异性的特点,导致叠层结构件的高效低损伤精密加工成为技术难题。而切削力与叠层结构件几何学、运动学、力学与动力学等方面的参数息息相关,能够直接反映加工参数-制孔质量之间作用规律。因此,通过分析刀具与工件在不同尺度下的力学行为而建立的切削力预测模型,对阐明叠层结构去除机制,进而提高叠层结构件一体化制孔质量至关重要。基于此,首先分析了叠层结构件制孔过程中各组成结构与材料特性、刀具几何结构、切削运动学与制孔系统对切屑成型过程的影响规律,揭示了叠层结构件切削过程的材料去除机制。其次,系统总结了叠层结构件一体化制孔切削力模型的研究现状,通过经典切削力模型、刀具离散化模型、切削量计算、动态切削角计算与制孔阶段划分五个重要方面,阐述了解析模型的相关建模方法。进一步的,综合分析了其他切削力模型如经验模型、有限元模型以及智能模型在叠层结构一体化制孔中的应用,并从刀具运动轨迹、未变形切屑厚度、切屑成型等角度,分析了超声辅助制孔的材料去除机制与切削力特性。最后,针对叠层结构件一体化制孔过程去除机制和切削力模型,分析了潜在的研究难点与发展趋势,以期深入完善叠层结构低损伤切削准则,并建立一体化制孔成屑理论框架,从而推动切削力模型的发展。

     

    Abstract: Carbon fiber reinforced plastics/light alloy laminated structural parts have become the first choice for key load-bearing structural parts in the aerospace field due to their high specific strength, high specific modulus and high fracture toughness. In order to ensure the processing efficiency and hole-making quality of the overall structural parts, it is urgent to carry out integrated hole-making processing for laminated structural parts. However, carbon fiber reinforced plastics, light metals and their laminated interfaces are discontinuous, heterogeneous and anisotropic, which makes the high-efficiency and low-damage precision machining of laminated structures a technical difficult problem. The cutting force is closely related to the parameters of geometry, kinematics, mechanics and dynamics of laminated structures, which can directly reflect the action law between the processing parameters and the hole quality. Therefore, the cutting force prediction model, which created by analyzing the mechanical behavior of tools and workpieces at different scales, is very important to clarify the removal mechanism of the laminated structure and further improve the quality of integrated drilling of laminated structural parts. Based on this, firstly, the influence of each component structure and material characteristics, tool geometry, cutting kinematics and drilling system on the chip forming process during the drilling process of laminated structural parts is analyzed, and the material removal mechanism of the cutting process of laminated structural parts is revealed. Secondly, the research status of the cutting force model for the integrated drilling of laminated structural parts is systematically summarized. The relevant modeling methods of the analytical model are elaborated from the five important aspects of classical cutting force model, tool discretization model, cutting amount calculation, dynamic cutting angle calculation and drilling stage division. Furthermore, the application of other cutting force models such as empirical model, finite element model and intelligent model in the integrated drilling of laminated structure is comprehensively analyzed. The material removal mechanism and cutting force characteristics of ultrasonic assisted drilling are analyzed from the perspectives of tool trajectory, undeformed chip thickness and chip forming. Finally, the potential research difficulties and development trends are analyzed for the removal mechanism and cutting force model of the integrated drilling process of laminated structures, in order to further improve the low-damage cutting criterion of laminated structures and establish the theoretical framework of chip formation theory for integrated drilling processing so as to promote the development of cutting force model.

     

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