（机械工程专业毕业论文）碳纤维增强树脂基复合材料铣削加工性能研究.docx

碳纤维增强树脂基复合材料铳削加工性能研究碳纤维增强树脂基复合材料铳削加工性能研究摘要碳纤维增强树脂基复合材料以轻质高强、耐高温、抗腐蚀等优良特性被广泛用作结构材料及耐高温材料，从以前主要集中在航天航空及军事领域，逐步拓展到工业应用领域，但其各向异性、非均匀性及脆性大等特点使其在切削加工过程中容易出现分层、撕裂及表面不平整等缺陷，而且其高硬度及导热性差等特点导致切削过程中刀具磨损严重，属于典型的难加工材料。高速切削是集高效率、低成本、和低能耗等优点于一身的先进制造技术，其最主要的应用领域就是解决难加工材料的切削加工。因此，有必要对碳纤维复合材料铳削加工性能进行研究，以期为高速铳削碳纤维复合材料及其刀具的选择提供理论依据。本文主要利用实验研究的方法，采用整体式硬质合金及其涂层（A1CrN、TiA1N）立铳刀，对高速铳削碳纤维复合材料切削力、表面粗糙度及刀具磨损进行了深入的研究。研窕结果表明：各铳削分力均呈类正弦曲线周期性波动；涂层刀具的切削力明显小于无涂层刀具，且能获得较好的表面粗糙度；不同材料刀具下切削参数对切削力和表面粗糙度的影响基本一致，切削力和表面粗糙度皆随切削深度及每齿进给量的增大而增大。总体上切削力随着切削速度的增大而增大；然而，随着切削速度的增大，表面粗糙度先减小后增大。对TiaIN涂层刀具切削力频域分析可知，总体上，主轴不平衡力幅值及切削力幅值皆随切削速度的升高而降低，但当切削速度为450mmin时，Y向主轴不平衡力幅值急剧变大。主轴旋转不平衡力及切削力频率响应函数主要频率随着切削速度的增大呈线性递增趋势；刀齿切入频率为主轴旋转频率的二次谐波。每齿进给量对进给力FX影响最为显著、切削深度次之，切削速度影响不显著；每齿进给量对切向力Fy影响最为显著、切削速度次之，切削深度影响最小;每齿进给量对表面粗糙度影响最为显著、切削速度次之，切削深度对表面粗糙度影响不大。刀具磨损主要受切削速度和每齿进给量影响，切削深度对其影响不大;刀具磨损量随切削速度、每齿进给量的增大而增大。最后，分别建立了碳纤维复合材料切削分力Fx,Fy及表面粗糙度和刀具磨损经验模型。最后，通过扫描电镜、能谱分析，深入研究了三种不同材料刀具的磨损机理,金属切削典型的月牙洼磨损并未出现，前刀面均发生了轻微的切屑黏附，硬质合金无涂层刀具切屑黏附异常严重，并发生了崩刃现象。磨损区域皆呈现抛光状的磨损带，且沿切削方向有轻微的沟痕，涂层刀具后刀面涂层剥落现象明显。三种刀具的磨损机理主要为磨粒磨损和粘着磨损。关键词：碳纤维增强树脂基复合材料，铳削，表面粗糙度，切削力，刀具磨损TheMi11ingPerformanceStudyofCarbonFiberReinforcedResinMatrixCompositesAbstractCarbonfiberreinforcedresinmatrixcompositeswith1ightweight,highstrength,hightemperatureresistant,anticorrosioncharacteristicsarewide1yusedasstructura1materia1sandhightemperatureresistantmateria1.Fromthepreviousfocusonaerospaceandmi1itaryfie1ds,thecompositegradua11yexpandtoindustria1app1ications.Buttheyarethetypica1difficu1t-to-machinemateria1s.Theheterogeneity,anisotropyand1argebritt1enessmakeitpronetosurfacedefectssuchasde1amination,tearinganduneveninmachiningprocess.Anditshighhardnessandpoorheatconductivitycharacteristics1eadtoserioustoo1wear.Highspeedcuttingwiththeadvantagesofhighefficiency,1owcost,and1owenergyconsumptionisanadvancedmanufacturingtechno1ogy.Itsmainapp1icationfie1dsistoso1vethemachiningofdifficu1t-to-machinemateria1s.Therefore,forprovidingtheoretica1evidenceofhighspeedmi11ingcarbonfibercompositemateria1sandse1ectionofcuttingtoo1,itisnecessarytostudytheperformanceofmi11ingofcarbonfibercompositemateria1s.Thispapermain1yadoptsthemethodofexperimenta1research,usingtheintegra1cementedcarbideanditscoating(A1CrN,TiAIN)cutterstoresearchthecuttingforce,surfaceroughnessandtoo1wearinhighspeedmi11ingcarbonfibercompositemateria1.Theresu1tsshowthatthemi11ingforcecomponentiscyc1ica1f1uctuationassinecurve;ThecuttingforceofCoatedtoo1sis1essthanuncoatedtoo1s,anditcanobtainbettersurfaceroughness.Underdifferenttoo1s,theinf1uenceofcuttingparametersoncuttingforceandsurfaceroughnessarea1mostthesame.Cuttingforceandsurfaceroughnessincreasewithcuttingdepthandfeedpertooth.Overa11,cuttingforceincreaseswithcuttingspeed,butthetrendofincreaseiss1ow1y.However,thesurfaceroughnessdecreasewiththeincreaseofcuttingspeedatfirstandthenincrease.Theresu1tsofcuttingforcespectrumana1ysisofTiA1Ntoo1sintheexperimentshowthatingenera1,theamp1itudeofspind1eunba1ancedforceandcuttingforcedecreasewiththeincreaseofcuttingspeed,butwhenthecuttingspeedisupto450mmin,theamp1itudeofY-axisspind1eunba1ancedforcesharp1yincreases.Spind1eunba1anceforceandmainfrequencyofcuttingforcefrequencyresponsefunctionincreased1inear1ywiththeincreaseofcuttingspeed;thetoothpassingfrequencyisthesecondharmonicfrequencyforthespind1efrequency.Feedpertoothhasthemostdominantro1eininf1uencingthefeedforceFx,fo11owedbyeffectofcuttingdepthandtheeffectofcuttingspeedisneg1igib1e.Feedpertoothhasthemostdominantro1eininf1uencingthetangentia1forceFy,fo11owedbycuttingspeedandtheeffectofcuttingdepthisneg1igib1e.Feedpertoothhasmost1yinf1uencedthesurfaceroughness,fo11owedbycuttingspeedandtheeffectofcuttingdepthhasbeenfoundtobeneg1igib1e.Too1wearismain1yinf1uencedbyfeedpertoothandcuttingspeed,andtheeffectofcuttingdepthofisnotbig.Too1wearincreaseswithcuttingspeedandfeedpertooth.Fina11y,estab1ishedthemode1ofcuttingforceFx,Fy,surfaceroughnessandtoo1wear,respective1y.At1ast,thetoo1wearmechanismofthreedifferentmateria1swasfurtherstudiedbyscanninge1ectronmicroscopy(SEM)andenergyspectrumana1ysis.Therewasnotypica1craterwearofmeta1cuttingonrakeface.Therakefaceappeareds1ightchipadhesion,buttheadhesionofuncoatedcementedcarbidetoo1isunusua11ysevere,andappearthephenomenonofco11apseedge.Wearareasareshowingwearandtear1ikepo1ishedbandandtherehass1ightgrooveoncuttingdirection.Thecoatingf1akingisobviousonf1ankfaceofcoatedtoo1.Thewearmechanismofthreedifferenttoo1saremain1yabrasivewearandadhesionwear.Keywords:Carbonfiberreinforcedresinmatrixcomposites,Mi11ing,Surfaceroughness,Cuttingforce,Too1wear目录摘要AbstractII第一章绪论11.1 课题研究的背景及意义11.2 高速切削技术概述11.3 碳纤维复合材料及应用发展31.4 碳纤维复合材料切削研究41.4.1 碳纤维复合材料切削力研究41.4.2 碳纤维复合材料表面质量研究51.4.3 碳纤维复合材料刀具及磨损研究61.5 课题来源及主要研究内容8第二章高速铳削碳纤维复合材料实验设计92.1 实验系统92.1.1 工件材料的选择92.1.2 实验刀具选择102.1.3 切削机床的选择102.1.4 切削用量选择112.1.5 铳削方式的选择122.2 实验条件及实验方案设计122.2.1 高速铳削碳纤维复合材料切削力实验122.2.2 高速铳削碳纤维复合材料表面粗糙度实验152.2.3 高速铳削碳纤维复合材料刀具磨损实验162.3 本章小结17第三章高速铳削