机械工程学报 >

2018 , Vol. 54 >Issue 3: 186 - 195

DOI: https://doi.org/10.3901/JME.2018.03.186

制造工艺与装备

CFRP复合材料铣削力、温度及表层损伤分析

  • 王福吉 ,
  • 殷俊伟 ,
  • 贾振元 ,
  • 马建伟 ,
  • 徐震宇 ,
  • 王东
展开
  • 1. 大连理工大学精密与特种加工教育部重点实验室 大连 116024;
    2. 中国兵器工业集团内蒙古第一机械集团有限公司 包头 014030
王福吉,男,1974年出生,博士,教授,博士研究生导师。主要研究方向为复合材料去除机理与损伤成因。E-mail:wfjsll@dlut.edu.cn;殷俊伟,男,1986年出生,博士研究生。主要研究方向为复合材料加工损伤形成机制及其抑制技术。E-mail:dlyjw@mail.dlut.edu.cn;贾振元,男,1963年出生,博士,教授,博士研究生导师,长江学者特聘教授。主要研究方向为复合材料构件加工理论与工艺。E-mail:jzyxy@dlut.edu.cn

收稿日期: 2017-06-30

  修回日期: 2017-09-20

  网络出版日期: 2018-02-05

基金资助

国家自然科学基金（U1508207，51575082，51621064）、国家973计划课题（2014CB046503）、基本科研业务费（DUT16TD01）和国家科技重大专项（2016ZX04001-002）资助项目。

收起

Measurement and Analysis of Cutting Force, Temperature and Cutting-induced Top-layer Damage in Edge Trimming of CFRPs

  • WANG Fuji ,
  • YIN Junwei ,
  • JIA Zhenyuan ,
  • MA Jianwei ,
  • XU Zhenyu ,
  • WANG Dong
Expand
  • 1. Key Laboratory for Precision and Non-traditional Machining Technology of the Ministry of Education, Dalian University of Technology, Dalian 116024;
    2. Inner Mongolia First Machinery Group Corporation Limited, Baotou 014030

Received date: 2017-06-30

  Revised date: 2017-09-20

  Online published: 2018-02-05

Fold

摘要

碳纤维增强树脂基复合材料（Carbon fiber reinforced polymer，CFRP）以其轻质、高强等优点，在航空航天高端装备上展现出巨大优势。然而，CFRP中各组成相所需的切削能量及热导率具有差异性，在切断高强纤维的同时极易造成低强的纤维/树脂界面发生开裂，而热量积聚所引起的高温又会使树脂软化加剧裂纹扩展，严重影响装备的服役性能和可靠性。阐明切削力和切削热对加工损伤的影响机制是实现CFRP高质高效加工的关键。基于数字图像处理技术，建立CFRP铣削加工表层损伤面积评价方法，该方法可有效避免传统方法因只能考虑损伤的一维长度信息而无法评价加工损伤程度的问题。分析主轴转速和每齿进给对表层损伤面积、切削力以及切削温度的影响规律，并讨论切削力和切削温度对表层损伤面积因子的影响。研究表明：通过减小单次切削厚度和控制切削温度在适合区间可有效降低加工损伤。

关键词： 碳纤维复合材料; 铣削; 损伤; 切削力; 切削温度

本文引用格式

王福吉 , 殷俊伟 , 贾振元 , 马建伟 , 徐震宇 , 王东 . CFRP复合材料铣削力、温度及表层损伤分析[J]. 机械工程学报, 2018 , 54(3) : 186 -195 . DOI: 10.3901/JME.2018.03.186

Abstract

Carbon fiber reinforced polymer (CFRP) composites have a great advantage in the fields including aeronautics and astronautics for their light weight and high strength, when compared to the more conventional materials. However, the cutting energy and the heat conductivity are serious difference between fibers and resin phases. Consequently, when cutting off the high-strength fibers, it is prone to provide problems like crack for the low-strength interface. Besides, heat accumulation may cause resin softening, which in turn deteriorates the crack growth. In some cases, the crack has a strong impact on the service performance and reliability of final parts. To solve the problems encountered in realizing the high quality and efficiency when machining of CFRP composites, the mechanism of damage formation under the combined effects of cutting force and cutting heat should be clarified first. In the current paper, a novel method to evaluate the damage extent on the top layer of CFRP composites is developed. This method can replace the conventional assessment approach of damage extent, which can only taking the maximum length of damage into account. Afterwards, the influences of cutting parameters on the damage, cutting force and cutting temperature are analyzed. The effects of cutting force and cutting temperature on the damage formation is also discussed. It suggests that reducing the single cutting thickness and controlling the cutting temperature in the reasonable range are the effective approach to improve machining quality.

Key words： carbon fiber reinforced polymer (CFRP); edge trimming; damage; cutting force; cutting temperature

参考文献

[1] 杜善义. 先进复合材料与航空航天[J]. 复合材料学报, 2007(1):1-12. DU Shanyi. Advanced composite materials and aerospace engineering[J]. Acta Materiae Compositae Sinica, 2007(1):1-12.
[2] CHE Demeng, SAXENA I, HAN Peidong, et al. Machining of carbon fiber reinforced plastics/polymers: a literature review[J]. Journal of Manufacturing Science & Engineering, 2014, 136(3):034001.
[3] LIU Defu, TANG Yongjun, CONG Weilong. A review of mechanical drilling for composite laminates[J]. Composite Structures, 2012, 94(4):1265-1279.
[4] STONE R, KRISHNAMURTHY K. A neural network thrust force controller to minimize delamination during drilling of graphite-epoxy laminates[J]. International Journal of Machine Tools & Manufacture, 1995, 36(9):985-1003.
[5] HOCHENG H, DHARAN C K H. Delamination during drilling in composite laminates[J]. Transactions-American Society of Mechanical Engineers Journal of Engineering for Industry, 1990, 112(3):236-239.
[6] TSAO C C, HOCHENG H. Effect of eccentricity of twist drill and candle stick drill on delamination in drilling composite materials[J]. International Journal of Machine Tools & Manufacture, 2005, 45(2):125-130.
[7] JAIN S, YANG D C H. Effects of feedrate and chisel edge on delamination in composites drilling[J]. Transactions-American Society of Mechanical Engineers Journal of Engineering for Industry, 1993, 115:398-398.
[8] GURURAJA S, RAMULU M. Modified exit-ply delamination model for drilling FRPs[J]. Journal of Composite Materials, 2009, 43(5):483-500.
[9] HINTZE W, HARTMANN D. Modeling of delamination during milling of unidirectional CFRP[J]. Procedia CIRP, 2013, 8:444-449.
[10] 周井文, 陈燕, 傅玉灿, 等. 纤维切削角对CFRP加工缺陷的影响规律[J]. 哈尔滨工业大学学报, 2015, 47(7):110-116. ZHOU Jingwen, CHEN Yan, FU Yucan, et al. Influence of fiber cutting angle on the machining defects during slotting of CFRP[J]. Journal of Harbin Institute of Technology, 2015, 47(7):110-116.
[11] SOLDANI X, SANTIUSTE C, MUÑOZ-SÁNCHEZ A, et al. Influence of tool geometry and numerical parameters when modeling orthogonal cutting of LFRP composites[J]. Composites Part A:Applied Science and Manufacturing, 2011, 42(9):1205-1216.
[12] BHATNAGAR N, NAYAK D, SINGH I, et al. Determination of machining-induced damage characteristics of fiber reinforced plastic composite laminates[J]. Materials and Manufacturing Processes, 2004, 19(6):1009-1023.
[13] RAO G V G, MAHAJAN P, BHATNAGAR N. Micro-mechanical modeling of machining of FRP composites–Cutting force analysis[J]. Composites Science and Technology, 2007, 67(3):579-593.
[14] CALZADA K A, KAPOOR S G, DEVOR R E, et al. Modeling and interpretation of fiber orientation-based failure mechanisms in machining of carbon fiber-reinforced polymer composites[J]. Journal of Manufacturing Processes, 2012, 14(2):141-149.
[15] 殷俊伟, 贾振元, 王福吉,等. 基于CFRP切削过程仿真的面下损伤形成分析[J]. 机械工程学报, 2016, 52(17):58-64. YIN Junwei, JIA Zhenyuan, WANG Fuji, et al. FEM Simulation Analysis of Subsurface Damage Formation Based on Continuously Cutting Process of CFRP[J]. Journal of Mechanical Engineering, 2016, 52(17):58-64.
[16] YASHIRO T, OGAWA T, SASAHARA H. Temperature measurement of cutting tool and machined surface layer in milling of CFRP[J]. International Journal of Machine Tools and Manufacture, 2013, 70:63-69.
[17] BRINKSMEIER E, FANGMANN S, RENTSCH R. Drilling of composites and resulting surface integrity[J]. CIRP Annals-Manufacturing Technology, 2011, 60(1):57-60.
[18] KIM H S, WANG Wenxue, TAKAO Y. Evaluation by FEM of temperature-dependent damage behavior in quasi-isotropic carbon/epoxy laminates[J]. Advanced Composite Materials, 1999, 8(3):247-257.
[19] PECAT O, RENTSCH R, BRINKSMEIER E. Influence of milling process parameters on the surface integrity of CFRP[J]. Procedia CIRP, 2012(1):466-470.
[20] 张厚江, 陈五一, 陈鼎昌. 碳纤维复合材料(CFRP)钻孔出口缺陷的研究[J]. 机械工程学报, 2004, 40(7):150-155. ZHANG Houjiang, CHEN Wuyi, CHEN Dingchang. Investigation of the exit defects in drilling carbon fiber-reinforced plastic plates[J]. Journal of Mechanical Engineering, 2004, 40(7):150-155.
[21] 周正干, 孙广开, 李征, 等. 复合材料层压板钻孔分层激光超声检测方法[J]. 机械工程学报, 2013, 49(22):29-33. ZHOU Zhenggan, SUN Guangkai, LI Zheng, et al. Laser ultrasonic detection of drilling-induced delamination in composite laminates[J]. Journal of Mechanical Engineering, 2013, 49(22):29-33.
[22] DAVIM J P, REIS P. Damage and dimensional precision on milling carbon fiber-reinforced plastics using design experiments[J]. Journal of Materials Processing Technology, 2005, 160(2):160-167.
[23] 王奔, 高航, 郭东明. 树脂固化温度与纤维铺设方式对C/E复合材料制孔质量的影响[J]. 机械工程学报, 2011, 47(12):19-25. WANG Ben, GAO Hang, GUO Dongming. Influence of resin cure temperature and fiber lay-up style on the drilling quality of C/E composites[J]. Journal of Mechanical Engineering, 2011, 47(12):19-25.
[24] CONG Weilong, ZOU Xiaotian, DEINES T W, et al. Rotary ultrasonic machining of carbon fiber reinforced plastic composites: An experimental study on cutting temperature[J]. Journal of Reinforced Plastics and Composites, 2012, 31(22):1516-1525.
[25] WANG Fuji, YIN Junwei, MA Jianwei, et al. Effects of cutting edge radius and fiber cutting angle on the cutting-induced surface damage in machining of unidirectional CFRP composite laminates[J]. The International Journal of Advanced Manufacturing Technology. 2017, 91(9):3107-3120.
Options
文章导航

/

〈 〉

版权所有 © 《机械工程学报》编辑部

技术支持：北京玛格泰克科技发展有限公司