微细铣削铝合金6061表面毛刺研究

Investigation on Burrs on Micro Milled Aluminum Alloy 6061

目的揭示微细铣削铝合金6061过程中,铣削工艺参数(切削深度a_p、每齿进给量f_z、切削速度v)、顺逆铣方式、刀具磨损对毛刺大小及形态的影响规律,为控制铝合金6061毛刺,提高表面质量,优化切削工艺提供参考。方法基于单因素试验方法,采用涂层硬质合金微直径铣刀,对铝合金6061进行了铣削加工试验,分别对切削参数单因素试验的逆铣、顺铣顶端毛刺大小数据以及刀具磨损、毛刺形态信息进行采集和分析。结果直观绘制了a_p、v、f_z对逆顺铣两侧顶端毛刺大小的影响规律图。单因素切削速度试验中,顺铣侧毛刺最大为323μm,逆铣侧最大为268μm;单因素每齿进给量试验中,顺铣侧毛刺最大为332μm,逆铣侧最大为331μm;单因素切深试验中顺铣侧毛刺最大为314μm,逆铣侧最大为264μm。结论逆铣比顺铣的顶端毛刺小,随切削深度增加,毛刺依次呈现长条须状、撕裂状、波浪形锯齿状。刀具磨损是造成切削过程不稳定的重要因素,同时也会造成毛刺形态和大小不稳定。为尽量减少毛刺,应采用锋利刀具和逆铣方式,控制切削深度,选择合适的切削速度和进给量。

The work aims to provide reference for controlling burrs on aluminum alloy 6061, improving surface quality and optimizing cutting process by revealing law of influences of milling process parameters （cutting depth ap, feed per tooth f~ and cutting speed v）, down and up milling methods as well as tool wear on burr size and shape during micro milling of aluminum alloy 6061. Based on single-factor test method, milling processing test was performed to aluminum alloy 6061 with mi- cro-diameter cutter for coated carbide, so as to collect and analyze such information as top burr size data, tool wear and burr shape for the single-factor test. A diagram indicating law of influences of ap, v and fz on the top burr size ob both sides of up/down milling was visually plotted. In the single-factor cutting speed test, the maximum burr size was 323 μm on down mil- ling side and 268 μm on up milling side; in the single-factor feed per tooth test, the maximum burr size was 332 μm on down milling side and 331 pm on up milling side; in the single-factor cutting depth test, the maximum burr size was 314 p.m on down milling side and 264 μm on up milling side. Top burr size on up milling side is smaller than that on down milling side. With the increase of cutting depth, burrs appear to be long fibrous, tearing and wavy serrated shape successively. Tool wear is an impor- tant factor leading to unstable cutting process. It can also cause unstable burr shape and size. Adopting sharp tools and up mil- ling, controlling cutting depth and selecting proper cutting speed and feed rate contribute to minimization of burrs.