金刚石涂层刀具高速铣铝合金平面切削毛刺研究

Research on cutting burrs in high speed milling of aluminum alloy plane with diamond coated tools

采用热丝CVD法制备纳米与微米金刚石薄膜涂层刀具,利用场发射扫描电镜表征其薄膜表面形貌。用已制备的CVD金刚石涂层刀具,在无润滑干切条件下高速顺、逆端铣铝合金平面,研究CVD金刚石涂层刀具切削时的棱边毛刺特点与大小;并对纳米金刚石涂层刀具高速顺铣切削工艺参数进行正交试验,探究取得少无切削毛刺的切削参数与切削工艺。结果表明:工件铣削后棱边毛刺分布不均匀,顺铣毛刺稀疏,尺寸较小,其中纳米金刚石涂层刀具顺铣棱边毛刺高度平均值为32.08μm,仅为微米金刚石涂层刀具顺铣毛刺高度的46.5%。纳米金刚石涂层刀具高速顺铣平面,对棱边毛刺影响最大的是v_(c),其次为v_(f),ae的影响最小,最优参数组合为a_(e)=4 mm、v_(f)=2000 mm/min、v_(c)=400 m/min,铣削后毛刺高度平均值为21.29μm。当金刚石涂层刀具端铣铝合金平面时,为取得较小的棱边毛刺,优选纳米金刚石涂层刀具,采用顺铣棱边的切削方式与切削工艺,以及相应的高速切削参数。

The nano and micro diamond film coated tools were prepared by the hot wire CVD method.The surface morphology of the film was characterized by field emission scanning electron microscopy.The prepared CVD diamond coated tools were used to end mill the aluminum alloy surface forward and backward at high speed under the condition of dry cutting without lubrication.It studies the characteristics and size of edge burrs during high-speed end milling of aluminum alloy using CVD diamond coated tools.It carries out orthogonal tests on cutting process parameters to explore the cutting parameters and processes with little or no cutting burr when nano-diamonds coated tools are used for high-speed forward milling.The results show that the distribution of burrs on the edges of the workpiece is uneven after milling,and the burrs during forward milling are sparse and small in size.Among them,the average height of burrs on the edges during forward milling with nano diamond coated tools is 32.08μm,only 46.5%of the forward milling burr height of micrometer diamond coated tools.When nano diamond coated tools are used for high-speed forward milling of flat surfaces,v_(c)has the greatest impact on edge burrs,followed by v_(f),and ae has the weakest impact.The optimal parameter combination for high-speed milling is ae=4 mm,v_(f)=2000 mm/min,and v_(c)=400 m/min.The average burr height after milling is 21.29μm.When the diamond coated tool is used to end mill the aluminum alloy plane,in order to obtain a small burr,the nano diamonds coated tool is selected,the cutting method of forward milling and the corresponding high-speed cutting parameters are adopted.