泡沫铝填充铣孔加工参数优化及表面质量验证

Optimization of Machining Parameters and Surface Quality Verification of Aluminum Foam Filling Milling Hole

为了提高泡沫铝铣孔质量,设置了不同类型的填充材料进行铣孔测试,对比了各铣孔加工参数下得到的表面结构与组织形态。研究结果表明:以松香和硬脂酸钠按照质量比4:1方式混合得到的泡沫铝加工后形成的孔嵴与孔径保形率分别达到了91.4%与96.8%,达到了最优保形状态。提高进给速度,孔尺寸与孔嵴保形率、透气性都表现为随进给速度提高而先升高再降低,当进给速度为160mm/min达到最大保形率,孔尺寸保形率为92.1%,孔嵴保形率为97.3%。在刀具转速达到300r/min时依然保持很高的保形率。按照氢化松香与硬脂酸钠质量比为4:1,转速310r/min以及进给速度165mm/min开展铣孔加工测试,可以使泡沫铝铣孔过程达到理想保形状态。该研究对提高泡沫金属的孔加工具有很好的实际指导意义,易于推广应用。

In order to improve the milling quality of aluminum foam holes,different types of filling materials were set up to test the milling holes,and the surface structure and microstructure morphology were compared under various milling parameters.The results show that the shape preserving rate of pore ridge and aperture formed by aluminum foam mixed with rosin and sodium stearate at the mass ratio of 4:1 reaches 91.4%and 96.8%respectively,reaching the optimal shape preserving state.When the feed rate was 160mm/min,the maximum shape preservation rate was reached,and the shape preservation rate of the hole size was 92.1%,and the shape preservation rate of the hole crest was 97.3%.When the tool speed is up to 300r/min,it still keeps high shape retention rate.According to the mass ratio of hydrogenated rosin to sodium stearate of 4:1,rotating speed of 310r/min and feeding speed of 165mm/min,the milling process of aluminum foam can reach the ideal shape preservation state.The research has a good practical guiding significance for improving the hole processing of foamed metal and is easy to be popularized and applied.