树脂基纤维复合材料钻削研究进展

主要介绍了树脂基纤维复合材料钻削过程中的钻削力、钻削温度、加工表面质量等钻削性能及材料去除机理、缺陷形成机理、刀具磨损机理等钻削机理方面的研究现状;阐述了树脂基纤维复合材料钻削工艺及钻头改进方面的最新研究进展,并对树脂基纤维复合材料钻削加工技术的下一步研究重点进行了展望。     

CFRP/TC4叠层板的钻削实验

采用硬质合金麻花钻对碳纤维复合材料-钛合金叠层板进行钻削试验,分析了钛合金层加工参数对刀具磨损的影响和刀具磨损机制。刀具磨损对孔入口处最大撕裂长度的影响。结果表明:磨损的主要区域是横刃和后刀面,前刀面磨损不明显。钛合金层的低转速和低进给量可以降低刀具磨损;此外随着钻孔数的增加,钛合金层转速越低、进给量越大碳纤维复合材料孔入口处孔质量更好。     

玻璃纤维复合材料钻削轴向力与分层分析

为研究玻璃纤维复合材料钻削轴向力与分层特征,以电镀金刚石钻头和硬质合金麻花钻为钻削工具,对玻璃纤维复合材料进行正交钻削实验,研究钻头的几何形状、刀具材质以及钻削工艺参数对玻璃纤维复合材料钻削轴向力和钻削质量的影响。结果表明,钻削工艺参数直接影响玻璃纤维复合材料的钻削轴向力和钻削质量,高转速、低进给速度和合适的刀具结构、刀具材质能够降低钻削轴向力并改善加工质量。电镀金刚石钻头的轴向力和出口分层损伤大于硬质合金麻花钻的钻削轴向力和钻削出口分层损伤,电镀金刚石钻头的结构优化可以有效改善钻削质量。     

CFRP/钛合金叠层材料制孔技术的现状与展望

综述了近年来国内外对CFRP/钛合金叠层材料制孔技术的研究进展,重点介绍了传统方法钻削CFRP/钛合金叠层材料过程中轴向力和扭矩、钻削温度的测量方法,轴向力和扭矩的变化规律,以及刀具磨损、加工损伤与钻削工艺的关系;对螺旋铣孔、低频振动钻孔和超声辅助振动钻孔的实现方法、运动特点和加工质量进行了分析总结,并对CFRP/钛合金叠层材料制孔技术的应用和研究动向进行了探讨。     

阶梯钻钻削钛合金实验

采用自主磨制的阶梯钻对钛合金进行钻削实验,并与普通麻花钻进行对比。分析了不同加工参数下的钻削力、切屑形态、孔径、孔壁表面粗糙度以及孔出入口毛刺。实验结果表明:钻削力随着主轴转速的增大而减小,随着进给量的增大而增大。相比普通麻花钻,阶梯钻产生的钻削力更小,切屑尺寸更小,排出顺畅,孔径值接近于钻头直径,孔壁表面粗糙度值更小,孔出入口毛刺少。     

飞机结构紧固孔制孔工艺对表面加工质量的影响

在简要介绍试验件及其紧固孔加工工艺的基础上,针对制孔工艺对紧固孔加工精度、表面粗糙度、加工硬化、加工残余应力的影响进行了深入地研究。     

纤维方向对CFRP钻削温度场分布和孔壁质量的影响

为研究CFRP不同纤维方向对其钻孔温度场分布和孔壁质量的影响,对不同纤维方向角处切削形式进行理论分析和ABAQUS仿真分析,并结合CFRP单向板、正交板和准各向同性板的钻削温度分布测试试验与钻削温度场仿真分析。结果表明,碳纤维方向对钻削温度场的分布规律影响很大;通过电子显微镜和共聚焦显微镜对不同纤维方向角处孔壁质量观测对比,发现纤维方向角在θ=0°、θ=45°和θ=90°处孔壁质量较好,在θ=135°处孔壁质量较差。     

CFRP-TC4叠层板的钻削实验

采用硬质合金麻花钻对CFRP-TC4叠层板进行钻削试验,分析了钛合金层加工参数对钻削力、钻削温度和加工孔质量的影响。结果表明:随着转速的增加,钛合金层的轴向力逐渐减小;随着钛合金层进给量的增加,钛合金层与CFRP层的轴向力之比逐渐增加。运用指数公式模型对钛合金层轴向力实验结果进行回归分析,得到轴向力与转速以及进给量之间的关系式:F_z=2 088n~(-0.1222)·f_r~(0.2016),并对该方程进行了检验验证,误差均小于10%;在钛合金层进给量不变时,随着钛合金层转速的增加,CFRP的最大烧伤环直径和层间最高温度逐渐增加。     

Ironing effect on surface integrity and fatigue behavior during ultrasonic peening drilling of Ti-6Al-4V

Imposing compressive residual stress field around a fastening hole serves as a universal method to enhance the hole fatigue strength in the aircraft assembly filed. Ultrasonic Peening Drilling (UPD) is a recently proposed hybrid hole making process, which can achieve an integration of strengthening and precision-machining with a one-shot-drilling operation. Due to the ironing effect of tool flank surface, UPD introduces large compressive residual stress filed in hole subsurface. In order to reveal the strengthening mechanism of UPD, the influence of ultrasonic vibration and tool dynamic relief angle on ironing coverage rate and its corresponding effect on surface integrity in UPD were analyzed. The experiments were conducted to verify the influence of ironing effect on surface integrity and fatigue behavior of Ti-6Al-4V hole in UPD. The results indicate that the specimen features smaller surface roughness, higher micro-hardness, plastic deformation degree and circumferential compress residual stress under higher ironing coverage rate. The fatigue life increases with the raise of ironing coverage rate, and the fatigue source site in UPD shifts from surface to subsurface comparing with that without vibration assistance. The results demonstrates that a better strengthening effect can be obtained by reasonably controlling the ironing coverage rate in UPD.     

Influence of lunar regolith compressibility on sampling performance of thick wall spiral drills

A 2 m class robotic drill was sent to the Moon and successfully collected and returned regolith samples in late 2020 by China. It was a typical thick wall spiral drill (TWSD) with a hollow auger containing a complex coring system to retain subsurface regolith samples. Before the robotic drill was launched, a series of laboratory tests were carried out to investigate and predict the possible drilling loads it may encounter in the lunar environment. This work presents how the sampling performance of the TWSD is affected by the regolith compressibility. Experiments and analysis during the drilling and sampling process in a simulated lunar regolith environment were conducted. The compressibility of a typical lunar regolith simulant (LRS) was measured through uni-directional compression tests to study the relationship between its inner regolith stress and bulk density. A theoretical model was established to elucidate the cutting discharge behavior by auger flights based on the aforementioned relationship. Experiments were conducted with the LRS, and the results show that the sampling performance is greatly affected by the flux of the drilled cuttings into the spiral flight channels. This work helped in scheduling reasonable drilling parameters to promote the sampling performance of the robotic drill in the Chinese Chang'E 5 mission.