超声切割铝蜂窝试验研究

Experimental Study on Ultrasonic Cutting of Aluminum Honeycombs

超声切割技术作为快速发展的加工工艺,越来越广泛地应用于复合材料的加工,尤其是以纸蜂窝材料为代表的弱刚度复合材料。开展了超声切割铝蜂窝试验研究,通过分析不同振幅、不同进给速度下的切割力、超声切割后蜂窝工件的宏观和微观形貌,验证了超声切割铝蜂窝的可行性和优势。试验结果显示,超声切割后蜂窝宏观结构无明显破坏,无明显毛刺毛边产生,提高超声振幅和进给速度可以改善蜂窝切割后微观表面形貌;刀具的超声振动可以显著减小切割力,且在相同进给速度下随着超声振幅的提高,切割力变小;在相同超声振幅下随着进给速度的提高,切割力变大,但变化幅度较小。通过对超声切割铝蜂窝过程的受力分析,讨论了超声振幅、进给速度的变化对切割力的影响规律,并与试验结果进行对比,从理论上分析了造成超声切割力规律性变化的内在原因。

As a rapidly developing processing technology, ultrasonic cutting technology is more and more widely used in the processing of composite materials, especially the low-rigidity composite materials represented by paper honeycomb material. Experiments are conducted to study the ultrasonic cutting of aluminum honeycomb. Through the analysis of the cutting force under different amplitudes and different feed speeds, and the macroscopic and microscopic topographies of the honeycomb workpieces after ultrasonic cutting, the feasibility and advantages of ultrasonic cutting of aluminum honeycomb are verified. The experimental results show that there is no obvious damages and no burrs on the macroscopic structures of honeycombs by ultrasonic cutting, and the microscopic surface topography can be improved by increasing the ultrasonic amplitude and the feed speed. The ultrasonic vibration of cutting tool can significantly reduce the cutting force, and with the increase of ultrasonic amplitude at the same feed speed, the cutting force becomes smaller. With the increase of the feed speed under the same ultrasonic amplitude, the cutting force becomes larger, but the change is small. Through the force analysis of ultrasonic cutting of aluminum honeycomb, the influences of ultrasonic amplitude and feed speed on cutting force are discussed and compared with experimental results. The internal reasons of ultrasonic cutting force variations are analyzed theoretically.