本文關(guān)鍵詞：超聲振動輔助銑削鈦合金工藝實(shí)驗(yàn)研究　出處：《南京理工大學(xué)》2017年碩士論文　論文類型：學(xué)位論文

  更多相關(guān)文章： TC4鈦合金 超聲振動輔助銑削 刀具磨損 銑削力 表面完整性

【摘要】：隨著航空航天工業(yè)的迅速發(fā)展,對鈦合金材料的需求日益提高,傳統(tǒng)的切削工藝已經(jīng)難以實(shí)現(xiàn)鈦合金高效高質(zhì)加工。超聲振動輔助加工是將超聲波信號引入到普通加工中,通過將電信號轉(zhuǎn)化為機(jī)械振動再傳遞給工件或刀具,使其實(shí)現(xiàn)斷續(xù)切削的加工效果,從而減小加工過程中的切削力、切削溫度,改善加工效率,提高加工質(zhì)量。目前該技術(shù)在陶瓷等硬脆材料的加工中體現(xiàn)出獨(dú)特優(yōu)勢,但在鈦合金的銑削加工中應(yīng)用較少。因此,本文以TC4鈦合金為對象,開展了超聲振動輔助銑削實(shí)驗(yàn)。分析了超聲振動輔助作用和工藝參數(shù)對刀具磨損、銑削力以及表面完整性的影響規(guī)律。首先,設(shè)計(jì)了超聲振動輔助銑削鈦合金的刀具磨損實(shí)驗(yàn),分析了銑削加工過程中刀具的磨損機(jī)理。通過對不同銑削時(shí)間下普通銑削和超聲振動輔助銑削的刀具磨損形貌進(jìn)行觀察和分析,發(fā)現(xiàn)超聲振動的輔助作用對加工過程中產(chǎn)生的刀具磨損有明顯的改善效果,并且能夠延長刀具使用壽命。同時(shí)對比了兩種加工方式下的鈦合金切屑形貌,發(fā)現(xiàn)超聲振動輔助銑削下的切屑微小細(xì)碎且呈均勻弧狀形態(tài)。其次,在不同的銑削參數(shù)下開展了超聲振動輔助銑削鈦合金的銑削力實(shí)驗(yàn),分析隨著銑削參數(shù)的變化,超聲振動作用對銑削力的影響規(guī)律。實(shí)驗(yàn)結(jié)果表明,超聲振動的輔助作用可降低鈦合金銑削過程中的最大銑削力和平均銑削力,并且在一定范圍內(nèi),超聲電流越大,銑削力越小。兩種加工方式下的銑削力都隨主軸轉(zhuǎn)速的增加而減小;隨著進(jìn)給速度及切削深度的增加而增大,但超聲振動的輔助使得銑削力增幅較為緩慢。此外,在實(shí)驗(yàn)基礎(chǔ)上建立了超聲振動輔助銑削鈦合金的銑削力指數(shù)預(yù)測模型,并對鈦合金銑削加工參數(shù)進(jìn)行了優(yōu)化。結(jié)果表明,所建的指數(shù)模型預(yù)測精度以及穩(wěn)定性均相對較高;優(yōu)化后的銑削力明顯減小,優(yōu)化效果顯著。最后,通過非接觸式3D形貌儀測量了不同加工參數(shù)下鈦合金的表面三維粗糙度。結(jié)果表明高頻的振動沖擊作用使得鈦合金加工表面更加細(xì)微且均勻,主軸轉(zhuǎn)速的增加有利于降低表面粗糙度,而切削深度對表面粗糙度影響較小。利用體視顯微鏡對兩種加工方式在不同銑削深度下的棱邊質(zhì)量進(jìn)行了分析。發(fā)現(xiàn)超聲振動輔助銑削加工后的棱邊質(zhì)量與普通銑削相比明顯有所改善,不僅毛刺的尺寸較小而且密集程度也遠(yuǎn)低于普通銑削;另外,隨著銑削深度的增大兩種加工方式下的邊緣毛刺均有一定程度的增加。利用X射線衍射儀測量了不同超聲電流下的鈦合金表面殘余應(yīng)力。結(jié)果表明,超聲振動輔助銑削表面形成的為殘余壓應(yīng)力,高頻的振動沖擊有利于提升加工表面的殘余壓應(yīng)力,并隨著超聲電流的增大呈現(xiàn)遞增趨勢。
[Abstract]:With the rapid development of the aerospace industry, the titanium alloy material of increasing demand, the traditional cutting process of titanium alloy has been difficult to achieve high quality processing. Ultrasonic vibration assisted machining is introduced into the ordinary ultrasonic signal processing, through the electrical signal into mechanical vibration transmitted to the workpiece or tool in the effect of intermittent cutting processing, and cutting force, in the process of reducing the cutting temperature, improve processing efficiency, improve the quality of processing. The technology in the processing of hard brittle materials such as ceramics embody the unique advantages, but in milling of titanium alloy in application. Therefore, in this paper, TC4 titanium alloy as the object. The ultrasonic vibration assisted milling experiments. Analysis of the effect of ultrasonic vibration and process parameters on tool wear, cutting force and surface integrity are studied. Firstly, the design of ultrasonic vibration The auxiliary tool wear in milling of titanium alloy, analyzed the mechanism of tool wear in milling. The morphology were observed and analyzed by means of tool wear in different milling time under ordinary milling and ultrasonic vibration assisted milling, found the auxiliary effect of ultrasonic vibration has significant effect on the tool processing process produces wear. And can prolong the service life of the cutter. At the same time compared the titanium alloy under two different processing chip chip morphology, found tiny fine under the ultrasonic vibration assisted milling and uniform arc shape. Secondly, the milling force experiment of ultrasonic vibration assisted milling of titanium alloy in different milling parameters, with the analysis of changes the influence of milling parameters, effect of ultrasonic vibration on milling force. The experimental results show that the auxiliary effect of ultrasonic vibration can reduce the milling process of titanium alloy The average milling force and milling force, and in a certain range, the greater the current ultrasonic milling force, milling force is small. Two kinds of processing modes with increasing spindle speed decreases; increased with increasing feed rate and cutting depth, but the ultrasonic vibration assisted milling force increased more slowly. In addition, to establish a prediction model of ultrasonic vibration assisted milling of titanium alloy milling force index based on the experimental data, and the processing parameters of milling of titanium alloy were optimized. The results showed that the index model prediction accuracy and stability are relatively high; the optimized milling force decreases, the optimization effect is obvious. Finally, through non contact measurement of surface morphology of 3D titanium alloy under different machining parameters of 3D roughness. The results show that the vibration frequency of the impact of the titanium alloy surface is more fine and uniform, the main shaft speed The increase is beneficial to reduce the surface roughness, and cutting depth on surface roughness is smaller. Effects of two kinds of processing methods in different milling depth of edge quality was analyzed by stereomicroscope. Ultrasonic vibration assisted milling after edge quality and ordinary milling than improved, not only small size of burr but the intensity is also much lower than the ordinary milling; in addition, with the increase of burr increased milling depth under two different processing to a certain degree. The titanium alloy surface residual stress under different ultrasonic current were measured using X ray diffraction. The results show that the ultrasonic vibration assisted milling surface compressive residual stress the impact of high frequency vibration, is beneficial to improve the machined surface residual compressive stress, and with the increase of current ultrasound showed an increasing trend.

【學(xué)位授予單位】：南京理工大學(xué)
【學(xué)位級別】：碩士
【學(xué)位授予年份】：2017
【分類號】：TG663;TG54

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