镍磷合金微沟槽金刚石切削泊松毛刺形成机理

Formation mechanism of Poisson's burr in micro-grooved diamond cutting of nickel-phosphorus alloy

为了探究镍磷合金超精密切削过程中泊松毛刺的形成原因及规律,并且寻求泊松毛刺尺寸更精准的表征方式,本文通过对镍磷合金泊松毛刺的形成机理进行理论分析,建立其正交切削过程中的泊松毛刺高度和宽度预测模型,并通过实验分析切削参数对泊松毛刺高度和宽度的影响,通过实验观察可知,切削深度对毛刺尺寸影响显著,切削深度由3μm增加至9μm时,毛刺高度增加了0.0998μm,毛刺宽度增加了1.06μm,而切削速度对毛刺高度及宽度的影响很小。且通过对比实验得到的毛刺数据和预测数据可知,毛刺高度和宽度预测模型的平均相对误差值分别为5.43%和8.17%,验证了预测模型的准确性。同时目前的泊松毛刺高度和宽度表征方法具有一定的误差,因此本文提出了利用积分法计算泊松毛刺体积的方法,并基于体积法建立了更准确的泊松毛刺尺寸表征方法,通过计算得到体积的预测模型平均相对误差值为4.81%,可知泊松毛刺体积的预测模型准确度相对更高。研究结果为镍磷合金正交切削过程中合理选择切削参数和泊松毛刺尺寸评估方法提供了理论指导。

In order to explore the formation causes and rules of Poisson's burr in ultra precision cutting of nickel-phosphorus alloy,and to seek a more accurate characterization method of Poisson's burr size,this paper conducted theoretical analysis of the formation mechanism of Poisson's burr in nickel-phosphorus al⁃loy and established a prediction model for the height and width of Poisson's burr in orthogonal cutting pro⁃cess.Through experimental analysis of the influence of cutting parameters on the height and width of Pois⁃son’s burr,it can be observed that the effect of cutting depth on burr size is significant.When the cutting depth increases from 3μm to 9μm,the burr height increases by 0.0998μm and the burr width increases by 1.06μm,while the cutting speed has little effect on the burr height and width.By comparing the burr data obtained from the experiment with the predicted data,it can be seen that the average relative error val⁃ues of the burr height and width prediction models are 5.43%and 8.17%,which verifies the accuracy of the prediction model.At the same time,the current characterization method of the height and width of Poisson's burr have certain errors.Therefore,this paper proposed a method for calculating the volume of Poisson's burr using the integration method,and established a more accurate characterization method of the size of Poisson's burr based on the volume method.The average relative error value of the predicted volume model is 4.81%,indicating that the accuracy of the Poisson's burr volume prediction model is rela⁃tively higher.The research results provide theoretical guidance for the rational selection of cutting parame⁃ters and Poisson's burr evaluation method in the orthogonal cutting process of nickel-phosphorus alloy.