SiC_p/Al复合材料高速铣削切削力模型建立

使用聚晶金刚石(PCD)刀具并采用正交试验设计法,对含不同体分比的碳化硅颗粒增强铝基复合材料(SiCp/2009Al)进行高速铣削试验。在测量切削力和切屑厚度的基础上,建立了剪切角、剪切应力和摩擦角的预测模型,并结合金属切削基本理论公式建立了切削力的预测模型。该模型包含铣削速度、每齿进给量、径向切宽、增强颗粒体分比等重要参数,模型对进给方向最大铣削力预测值的平均误差为5.9%,对铣刀径向切深方向最大铣削力预测值的平均误差为9.2%,皆高于普通经验公式的预测精度,从而可对SiCp/2009Al复合材料高速铣削时的铣削力进行有效预测。

High-Speed Milling-Force Model for SiC_p /Al Composites

Highspeed milling tests are carried out on the SiCp/Al composites with different volume fraction using PCD tools at dry machining condition by the method of orthogonal experiments design. Prediction model of shear angle, shear stress and frictional angle are established on the foundation of cutting forces and chip thickness measuring. The prediction model of millingforces is also established according to the basic theory of metal cutting formula. This model contains the important parameters, such as cutting speed, feed rate, radial cut- ting width and volume fraction of SiC particle. Using this model, mean error of predictive value of maximum cutting force in the feed direction and in the radial cutting depth direction are 5.9% and 9.2%, respectively. The prediction accuracy is considerably higher than that of the traditional empirical formulas. Therefore, the newly established model can accurately predict the cutting forces when high- speed milling SiCp/2009Al composites.