碳纤维增强PA6切向超声辅助砂带磨削表面质量与表层纤维完整性及取向分布研究

Study on surface quality, surface-layer fiber integrity and orientation distribution in tangential ultrasonic-assisted belt grinding of carbon fiber-reinforced PA6

  • 摘要: 短切碳纤维增强热塑性复合材料 (SFRTP) 在磨削过程中易出现纤维断裂、基体涂抹及热损伤等问题。为此,开展了碳纤维增强聚酰胺6 (CF/PA6) 切向超声辅助砂带磨削试验,研究超声振动与磨削参数对磨削温度、表面质量及表层纤维结构的影响。同时,建立温度相关弹性地基梁模型分析表层纤维响应机制。结果表明,切向超声振动因高频摩擦和PA6基体黏弹性耗散,使最高磨削温度由无超声条件下的25.0~36.0℃升高至33.6~57.0℃。该温升使界面失效倾向增强,表现为表层纤维剪断减少、偏转响应增加,从而提高纤维完整性与取向一致性。同时,超声引入的重复划擦与排屑增强作用有利于降低表面粗糙度。在砂带线速度3~4 m/s、磨削深度0.6 mm、超声振幅约45 μm条件下,表面粗糙度、纤维完整性和取向一致性均得到改善。研究结果可为SFRTP材料的高质量磨削加工提供工艺参考。

     

    Abstract: Fiber fracture, matrix smearing, and thermal damage tend to occur during the grinding of short carbon fiber-reinforced thermoplastic composites (SFRTP). To address these issues, tangential ultrasonic-assisted belt grinding experiments were conducted on carbon fiber-reinforced polyamide 6 (CF/PA6). The effects of ultrasonic vibration and grinding parameters on grinding temperature, surface quality, and surface-layer fiber structure were investigated. Meanwhile, a temperature-dependent beam-on-elastic-foundation model was established to analyze the response mechanism of surface-layer fibers. The results show that tangential ultrasonic vibration increases the maximum grinding temperature from 25.0-36.0℃ under the non-ultrasonic condition to 33.6-57.0℃ due to high-frequency friction and viscoelastic dissipation of the PA6 matrix. This temperature rise enhances the tendency for interfacial failure, leading to reduced fiber breakage and increased reorientation response in the surface layer, thereby improving fiber integrity and orientation consistency. Meanwhile, the repeated scratching and enhanced chip-removal effects introduced by ultrasonic vibration are beneficial for reducing surface roughness. Under the conditions of belt speeds of 3-4 m/s, a grinding depth of 0.6 mm, and an ultrasonic amplitude of approximately 45 μm, the surface roughness, fiber integrity, and orientation consistency are all improved. The results can provide process guidance for high-quality grinding of SFRTP materials.

     

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