纤维增强复合材料钻削热研究进展与展望

刘勇; 潘子韬; 周宏根; 景旭文; 李国超

doi:10.13801/j.cnki.fhclxb.20230227.003

纤维增强复合材料钻削热研究进展与展望

doi: 10.13801/j.cnki.fhclxb.20230227.003

江苏科技大学　机械工程学院，镇江 212100

基金项目: 国家自然科学基金(52105450)；江苏省高校基金项目(21KJB460016)

详细信息

通讯作者:
刘勇，博士，讲师，硕士生导师，研究方向为复合材料切削加工　E-mail: liuyong.1991.happy@just.edu.cn

中图分类号: TG52；TB332
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出版历程
- 收稿日期: 2022-11-29
- 修回日期: 2023-01-23
- 录用日期: 2023-02-19
- 网络出版日期: 2023-02-28
- 刊出日期: 2023-08-15

Review and prospect of drilling heat for fiber reinforced composite

School of Mechanical Engineering, Jiangsu University of Science and Technology, Zhenjiang 212100, China

Funds: National Natural Science Foundation of China (52105450); University Science Research Project of Jiangsu Province (21KJB460016)

摘要

摘要: 纤维增强复合材料(Fiber reinforced composites，FRC)钻削过程中产生的切削热及冷却策略对其工艺参数的优化与加工表面质量的控制起着至关重要的作用。本文从钻削热理论研究、钻削热对加工质量的影响研究、钻削热的影响因素与控制策略3个方面对FRC钻削热进行系统性的分析与概述。首先，综述了FRC钻孔过程中的钻削热形成机制、热传导与热损伤预测、切削热的数值模拟等理论研究。然后，阐述了FRC钻削热的主要测量方法及切削热对孔加工质量的影响，并探讨了FRC制孔的切削热影响因素及其辅助加工控制钻削热方法。最后，总结了当前FRC钻削热研究存在的问题及今后研究的重点。
- 纤维增强复合材料 /
- 钻削热 /
- 加工质量 /
- 钻削刀具 /
- 冷却控制方法
Abstract: The research on the generated cutting heat and cooling strategies plays a crucial role in the optimization of process parameters and the control of hole's surface quality in drilling of fiber reinforced composite (FRC). In this paper, the review and prospect on the drilling heat during drilling FRC is systematically analyzed and summarized from three aspects: The theoretical research of drilling heat, research on the influence of drilling heat on machining quality, influencing factors and control strategies of drilling heat during drilling. Firstly, the theoretical research of drilling heat formation mechanism, heat conduction and heat damage prediction, and numerical simulation of cutting heat in FRC drilling process were summarized. Then, the main measurement methods of FRC drilling heat and the effect of cutting heat on the quality of hole machining were introduced. Meanwhile, the influencing factors of cutting heat and its auxiliary processing methods to control FRC drilling heat were discussed. Finally, the current existing problems and key points on the next study of FRC drilling heat were summarized.
- fiber reinforced composites /
- drilling heat /
- machining quality /
- drilling tool /
- cooling control method

HTML全文

图 1 单向(UD)-碳纤维增强树脂基复合材料(CFRP)切削加工机制：(a) 刀具与纤维夹角；(b) 微观切削模型；(c) 四种切削模式^[28]

θ—Cutting direction; $\overrightarrow {V_{{\rm{c}}}} $—Cutting speed; $\overrightarrow k $—Fiber direction

Figure 1. Unidirectional (UD)-carbon fiber reinforced polymer (CFRP) cutting mechanism: (a) Angle between cutter and fiber; (b) Micro-cutting model; (c) Four cutting modes^[28]

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图 2 CFRP切削热来源示意图^[31]

1, 2, 3—First, second, third deformation region

Figure 2. Schematic diagram of cutting heat source of CFRP^[31]

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图 3 UD-CFRP钻削热传导模型^[33]

ω—Angular velocity; ν_f—Feed velocity of the drill; q₁—Heat flux load which comes from the major cutting edges and chisel edge; q₂—Heat flux load generated from the side edges; l_x—CFRP length; l_y—CFRP width; l_z—CFRP thickness; d—Tool diameter

Figure 3. UD-CFRP drilling heat conduction model^[33]

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图 4 CFRP切削热力耦合分析模型^[46]

S—Mises stress

Figure 4. Thermal-mechanical coupling analysis model of CFRP cutting^[46]

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图 5 基于微结构的CFRP切削有限元模型^[47]

EHM—Equivalent homogeneous material; L₁—Length of the first zone; L₂—Length of the second zone; L₃—Length of the third zone

Figure 5. Finite element model of CFRP cutting based on microstructure^[47]

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图 6 有无超声振动辅助加工模拟结果对比：(a) 刚开始切削CFRP时；(b) 切削CFRP时^[47]

TEMP—Temperature/℃

Figure 6. Comparison of simulation results with or without ultrasonic vibration: (a) Start cutting CFRP; (b) During cutting CFRP^[47]

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图 7 有限元研究主要类型分类：(a) (I) UD-CFRP^[51]；(II) 编织CFRP^[50]；(b) (III) 损伤预测^[56]；(IV) 温度预测^[54]

Figure 7. Classification of main types of finite element research: (a) (I) UD-CFRP^[51]; (II) Knitting CFRP^[50]; (b) (III) Damage prediction^[56]; (IV) Temperature prediction^[54]

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图 8 CFRP钻孔时的二维热传导有限元模拟结果(高温区由尺寸标注，温度高于180°C)：(a) 新刀具；(b) 磨损刀具^[52]

Figure 8. Two-dimensional finite element simulation results of heat conduction during drilling with CFRP (The high temperature zone is marked by dimensions, the temperature is higher than 180 C): (a) New tool; (b) Wear the cutting tools^[52]

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图 9 三种不同测温方法的实验原理图：(a) 刀具-工件热电偶法；(b) 工件嵌入热电偶法；(c) 热像仪测量法^[61]

PC—Personal computer

Figure 9. Experimental schematic diagram of three different temperature measurement methods: (a) Tool-workpiece thermocouple method; (b) Workpiece embedding thermocouple method; (c) Thermal imager measurement method^[61]

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图 10 CFRP钻孔的主要损伤形式^{[12, 66]}

Figure 10. Main damage forms of CFRP drilling holes^{[12, 66]}

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图 11 CFRP钻出口热像图：(a) 实验所用刀具；(b) 钻出口处随钻孔深度变化的热像图(其中左侧使用常规刀具，右侧为新型刀具)^[28]

Figure 11. Thermal images of CFRP drill hole: (a) Tool used in the experiment; (b) Thermal image of the drilling outlet with the change of drilling depth (In which conventional tools are used on the left side and new tools are used on the right side)^[28]

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图 12 轨道钻孔及其刀具示意图^[77]

a_p—Screw pitch of the helical path; D—Diameter of the peripheral cutting edges; e—Eccentricity of the helical path; d—Diameter of the milling part; R—Radius of the arc of the ODR tool; ODR—Orbital drilling and reaming

Figure 12. Schematic diagram of track drilling and its tools^[77]

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图 13 刀具改进方法^{[66, 78, 84]}

CLS——Cutting lip of the sawtooth

Figure 13. Tool improvement method^{[66, 78, 84]}

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图 14 进给速率和旋转速度对温度的影响：(a)两种钻头对比；(b)传统麻花钻；(c)具有锯齿结构的麻花钻^[28]

Figure 14. Influence of feed rate and rotation speed on temperature: (a) Comparison of two kinds of drill bits; (b) Traditional twist drill; (c) Twist drill with sawtooth structure^[28]

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图 15 最小润滑(MQL)辅助加工技术示意图：(a) 溢流润滑；(b) 最小润滑^[95]；(c) 最小润滑喷射方式^[66]

Figure 15. Schematic diagram of minimum quantity lubrication (MQL) auxiliary processing technology: (a) Overflow lubrication; (b) Minimum lubrication^[95]; (c) Minimum lubrication injection mode^[66]

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图 16 CFRP钻孔实验装置：(a) 干钻；(b) 最小润滑辅助钻孔；(c) 液氮辅助钻孔；(d) 液化二氧化碳辅助钻孔^[107]

Figure 16. CFRP drilling experimental device: (a) Dry drilling; (b) Minimum lubrication auxiliary drilling; (c) Liquid nitrogen assisted drilling; (d) Liquefied carbon dioxide assisted drilling^[107]

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图 17 旋转超声椭圆振动加工原理：(a) 旋转超声振动加工；(b) 旋转超声椭圆振动加工；(c) 切屑排出示意图^[22]

v_f—Feed speed; n_s—Spindle speed; A—Vibration amplitude; H—Local section view H—H

Figure 17. Principle of rotary ultrasonic elliptical vibration machining: (a) Rotary ultrasonic vibration machining; (b) Rotary ultrasonic elliptical vibration processing; (c) Schematic diagram of chip discharge^[22]

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表 1 切削热的数值模拟分析

Table 1. Numerical simulation analysis of cutting heat

Simulation scale	Object	Keyword	Reference
Micro-scale	UD-CFRP	Fiber orientation angle	[41]
	UD-CFRP	Ultrasonic vibration	[43]
	UD-CFRP	Temperature pretreatment	[26]
	3D braided composites	Thermal conductivity	[44]
	3D braided composites	Braiding angle	[45]
	3D braided composites	Elastic-plastic damage constitutive laws	[46]
	UD-CFRP	Stress concentration	[47]
Macro-scale	CFRP	Thermal damage area prediction	[48]
	Tool	Cutting tool structure design	[49]
	CFRP, GFRP	Temperature prediction	[50]
	AFRP	Temperature prediction	[51]
	CFRP	Intralaminar damage	[52]

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表 2 辅助加工控制温度研究

Table 2. Study on control temperature of auxiliary machining

Auxiliary method	Object	Subject	Reference
MQL	CFRP/Ti6Al4V	Torque, specific cutting energy, hole wall morphologies, burr	[89]
	CFRP/Ti6Al4V	Thrust force, delamination damage, tool wear,	[90]
	CFRP	torque, thrust force, delamination damage, hole diameter, roundness	[91]
LN2	CFRP	Hole wall morphologies, hole wall surface roughness, tool wear, thrust force	[92]
	CFRP, CFRPs	Torque, thrust force, delamination damage, hole diameter, roundness	[93]
	CFRPs	Hole wall surface roughness, roundness, cylindricity, delamination damage	[94]
	AFRP	Thrust force, delamination damage, burr, ablation	[95]
LCO₂	CFRP/Ti6Al4V	Hole diameter, power consumption	[96]
LCO₂	CFRP	Hole wall morphologies, hole wall surface roughness, torque	[97]
Air	CFRP	Burr, tear, tool wear	[98]
Ultrasonic vibration	CFRPs	Hole wall surface roughness, thrust force, torque, delamination damage, burr, tear	[108]
	CFRP	Thrust force	[43]
	CFRPs	Hole wall morphologies	[22]
	CFRP	Hole wall surface roughness, thrust force, delamination damage, burr, tear	[110]

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