微槽铣削加工毛刺的形成机理及其主动控制技术研究

发布时间：2018-05-10 08:25

本文选题：微槽铣削 + 毛刺　；参考：《江苏大学》2017年硕士论文

【摘要】：作为先进制造技术重点发展方向之一的微细切削技术,其已在三维化、柔性化、多样化、异型化等微型构件及产品的制造中得到了广泛的应用。切削过程中残留的毛刺成为影响和制约精密与超精密加工技术发展的关键性问题之一。本文基于微槽铣削加工实验,系统地开展了对毛刺形成及其控制技术的研究,主要内容及研究成果如下:(1)利用数值模拟软件(STC DEFORM-2D3D)对微铣铝合金(Al6061-T6)通槽的切出逆铣侧毛刺(B1)和顶部毛刺的形成与变化进行了仿真与分析。在2D仿真条件下,将切出逆铣侧毛刺(B1)的形成过程划分为5个阶段;在3D仿真条件下,将通槽顶部毛刺划分成挤压状和翻卷状两种类型的毛刺。(2)以?0.5mm微铣刀铣削铝合金(Al6061-T6)通槽实验为基础,研究了切削参数(刃圆半径、主轴转速、每齿进给量、轴向切深)对切出逆铣侧毛刺(B1)、切出底部毛刺(B2)、顶部逆铣侧毛刺(B8)尺寸变化的影响。在选用的切削参数范围内,分别给出了针对上述三种位置毛刺尺寸最小时的最优参数组合。数据分析结果显示满足条件的最优参数组合各不相同;通过对B1和B2尺寸叠加图的分析,发现了两种毛刺尺寸相互补偿的现象。(3)借助映射函数(Mapping Function)法和灰色关联(Grey Relation)法实现了对微槽铣削过程中四个响应特征(切出逆铣侧毛刺B1、切出底部毛刺B2、槽底表面粗糙度Ra、铣削分力Fx)的数值同步优化。两种同步优化方法预测的最优参数组合形式一致,但针对其中单一响应特征的数值优化中存在少量的差异。(4)开展了主动控制毛刺技术与方法的研究。通过对微槽铣削过程中刀具路径的规划,使得通槽顶部两侧均成为逆铣侧,对应的毛刺尺寸较小且分布均匀,从而实现了对该过程中毛刺主动控制的目的。同时也为实现其它位置毛刺的主动控制提供了重要的参考依据。本研究工作是国家自然科学基金资助项目(编号:51075192)的组成部分之一,文中的部分研究成果有助于丰富和发展微细切削毛刺形成与控制理论,可为实际生产加工提供一定的参考依据和应用价值。
[Abstract]:As one of the important developing directions of advanced manufacturing technology, micro cutting technology has been widely used in the manufacture of micro components and products such as 3D, flexibility, diversification and profilization. The residual burr in cutting process has become one of the key problems affecting and restricting the development of precision and ultra-precision machining technology. Based on the experiment of micro-groove milling, the research on burr formation and its control technology has been carried out systematically in this paper. The main contents and research results are as follows: 1) the formation and change of the top burr and the formation of the top burr are simulated and analyzed by using the numerical simulation software STC DEFORM-2D3D) for cutting out the reverse milling side burr (B1) and the top burr of the micro-milling aluminum alloy (Al6061-T6). Under 2D simulation condition, the formation process of cutting out side burr B1) is divided into five stages, and in 3D simulation condition, The top burr of the groove is divided into two types: extruding and rolling. The cutting parameters (radius of the cutting edge, rotation speed of the spindle, feed per tooth) are studied based on the experiments of milling aluminum alloy (Al6061-T6) with a 0.5 mm micro-milling cutter. The effect of axial cutting depth on the size change of B1, B _ 2, B _ 8 and B _ (1), B _ (1), B _ (2) and B _ (8), respectively. In the range of cutting parameters selected, the optimal combination of parameters is given for the minimum burr size of the three positions mentioned above. The results of data analysis show that the optimal parameter combinations that satisfy the conditions are different, and by the analysis of the size superposition diagram of B1 and B2, It is found that two kinds of burr sizes compensate each other. (3) with the help of mapping function method and grey correlation grey relation method, four response characteristics (cutting out side burr B1, cutting bottom burr B2 and bottom table) are realized in the process of micro-grooving milling (cutting out back milling side burr B1, cutting bottom burr B2, and trough bottom table). Surface Roughness Ra. milling FX numerical synchronization optimization. The optimal parameter combinations predicted by the two synchronous optimization methods are the same, but the techniques and methods of active burr control are studied for the numerical optimization of single response characteristics. Through the planning of tool path in the process of microgroove milling, the top side of the groove becomes the reverse milling side, the corresponding burr size is smaller and the burr distribution is uniform, thus realizing the purpose of active control of the burr in the process. It also provides an important reference for the active control of burrs in other positions. This work is one of the components of the project funded by the National Natural Science Foundation of China (No.: 510751922). Some of the research results in this paper are helpful to enrich and develop the theory of formation and control of fine cutting burr. It can provide certain reference basis and application value for actual production and processing.
【学位授予单位】：江苏大学
【学位级别】：硕士
【学位授予年份】：2017
【分类号】：TG54

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