高体分铝基碳化硅超声振动钻削的内孔表面质量试验研究

Experimental Study on Machining Surface Quality in Ultrasonic Vibration Drilling of High-volume Fraction SiC p/Al

针对高体分铝基碳化硅精密钻削加工技术难题,利用普通超声振动钻削(UVD)和超声振动啄式钻削(UVPD)两种工艺,通过均匀试验设计,对高体分铝基碳化硅套料钻削的内孔表面质量的变化规律及产生原因进行了深入的直观分析和回归分析。结果表明:高体分铝基碳化硅套料钻削时,内孔表面缺陷表现为SiC颗粒拔出、SiC颗粒破裂、Al基体塑性变形三种形式;采用UVD能够获得比普通钻削更好的内孔质量,而采用UVPD的表面粗糙度可比UVD降低20%以上,各工艺条件下表面缺陷特征的差异是导致内孔质量变化的根本原因;无论UVD还是UVPD,超声振幅和进给速度都是影响内孔质量的重要因素,增大超声振幅或降低进给速度都有利于提高内孔质量。

Due to material and processes,precision drilling of high-volume fraction SiC p/Al is still a key challenge in the field of mechanical machining.In this paper,two processes,common ultrasonic vibration drilling(UVD)and ultrasonic vibration peck-drilling(UVPD)are used to drill this material.By the methods of intuitive analysis and regression analysis of uniform experimental design,the change rules and formation reasons of the hole surface quality are investigated deeply.The results show that,when trepanning high-volume fraction SiC p/Al,the surface defects of the inner hole are manifested in three forms:SiC particle pull-out,SiC particle cracking and plastic deformation of the Al matrix.The hole surface quality of UVD is better than that of common drilling under experiment conditions,and the surface roughness of UVPD can be reduced by more than 20%compared with UVD.The differences in surface defect characteristics under two processes are the main cause of the change in hole surface quality.Regardless of UVD or UVPD,ultrasonic amplitude and feed speed are important factors affecting the hole surface quality.Increasing the ultrasonic amplitude or reducing the feed speed is beneficial to the improvement of the hole surface quality.