CFRP超声振动套磨钻孔高效排屑机理和实验

Mechanism and experiment on high-efficiency chip removal in ultrasonic vibration core drilling of CFRP

针对碳纤维增强复合材料(CFRP)在普通套磨钻孔(CCD)过程中,切屑粉尘粘刀和料芯堵刀导致的排屑效果较差而影响套磨加工效率和加工质量的问题,采用超声振动套磨钻孔(UVCD)新技术进行了CFRP高效套磨钻孔的基础理论和实验研究。从理论上分析了CFRP超声振动套磨钻孔原理和高效排屑机理,同时结合所设计的超声振动气钻和车床平台实验验证了CFRP超声振动套磨钻孔的高效排屑钻孔效果。结果表明:相比于CFRP普通套磨钻孔,超声振动套磨钻孔极大提高了切屑粉尘和料芯的排屑效果,有效防止了切屑粉尘粘刀和料芯堵刀现象,明显降低了12%~20%的钻削力、16%~24%的切削温度和33%~39%的孔表面粗糙度,明显改善了CFRP孔加工质量并且延长了套磨刀具使用寿命。

To solve the problems of poor chip removal effects like the chip adhesion and rod jamming of core drill tool that would have a significantly negative influence on machining efficiency and machining quality during common core drilling(CCD)process of carbon fiber reinforced plastics(CFRP)using a core drill,the novel ultrasonic vibration core drilling(UVCD)technology was employed so as to carry out the basic theory and experiment study of high-efficiency core drilling CFRP.The core drilling principle and high-efficiency chip removal mechanism of UVCD were analyzed by theoretical method,meanwhile the machining effects of high-efficiency chip removal in UVCD of CFRP was verified by experimental method with a designed ultrasonic vibration air drill and lathe platform.The results indicate that compared with the CCD of CFRP,in the UVCD process,the chip removal effects of chip and rod are greatly improved,the problems of chip adhesion and rod jamming of core drill tool are effectively prevented,the thrust force,cutting temperature and hole surface roughness decrease by 12%-20%,16%-24%and 33%-39%respectively,the machining quality of CFRP hole is obviously improved,and the tool life of core drill will be evidently prolonged.