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非共振振动辅助微铣削中刀具磨损抑制机制的研究

Investigation on the Tool Wear Suppression Mechanism in Non-Resonant Vibration-Assisted Micro Milling.

作者信息

Zheng Lu, Chen Wanqun, Huo Dehong

机构信息

Mechanical Engineering, School of Engineering, Newcastle University, Newcastle upon Tyne NE1 7RU, UK.

Centre for Precision Engineering, Harbin Institute of Technology, Harbin 150001, China.

出版信息

Micromachines (Basel). 2020 Apr 3;11(4):380. doi: 10.3390/mi11040380.

DOI:10.3390/mi11040380
PMID:32260171
原文链接:https://pmc.ncbi.nlm.nih.gov/articles/PMC7231048/
Abstract

Excessive tool wear during hard and brittle material processing severely influences cutting performance. As one of the advanced machining technologies, vibration-assisted micro milling adds high-frequency small amplitude vibration on a micro milling tool or workpiece to improve cutting performance, especially for hard and brittle materials. In this paper, the tool wear suppression mechanism in non-resonant vibration-assisted micro milling is studied by using both finite element simulation and experiment methods. A finite element model of vibration-assisted micro milling using ABAQUS is developed based on the Johnson cook material and damage models. The tool-workpiece separation conditions are studied by considering the tool tip trajectories. The machining experiments are carried out on Ti-6Al-4V with a coated micro milling tool (fine-grain tungsten carbide substrate with ZrO2-BaCrO4 (ZB) coating) under different vibration frequencies (high, medium, and low) and cutting states (tool-workpiece separation or non-separation). The results show that tool wear can be reduced effectively in vibration-assisted micro milling due to different wear suppression mechanisms. The relationship between tool wear and cutting performance is studied, and the results indicate that besides tool wear reduction, better surface finish, lower burrs, and smaller chips can also be obtained as vibration assistance is added.

摘要

在硬脆材料加工过程中，刀具过度磨损会严重影响切削性能。作为先进加工技术之一，振动辅助微铣削在微铣刀或工件上叠加高频小振幅振动以提高切削性能，尤其适用于硬脆材料。本文采用有限元模拟和实验方法研究了非共振振动辅助微铣削中的刀具磨损抑制机理。基于Johnson cook材料和损伤模型，利用ABAQUS开发了振动辅助微铣削的有限元模型。通过考虑刀尖轨迹研究了刀具与工件的分离条件。采用涂层微铣刀（ZrO2-BaCrO4（ZB）涂层的细晶粒硬质合金基体）在不同振动频率（高、中、低）和切削状态（刀具与工件分离或不分离）下对Ti-6Al-4V进行了加工实验。结果表明，由于不同的磨损抑制机理，振动辅助微铣削可有效降低刀具磨损。研究了刀具磨损与切削性能之间的关系，结果表明，除了减少刀具磨损外，增加振动辅助还可获得更好的表面光洁度、更低的毛刺和更小的切屑。

https://cdn.ncbi.nlm.nih.gov/pmc/blobs/1980/7231048/c380a7ef1342/micromachines-11-00380-g016.jpg
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https://cdn.ncbi.nlm.nih.gov/pmc/blobs/1980/7231048/6009c87825c1/micromachines-11-00380-g006.jpg
https://cdn.ncbi.nlm.nih.gov/pmc/blobs/1980/7231048/742b142de0d3/micromachines-11-00380-g007.jpg
https://cdn.ncbi.nlm.nih.gov/pmc/blobs/1980/7231048/86b13f999797/micromachines-11-00380-g008.jpg
https://cdn.ncbi.nlm.nih.gov/pmc/blobs/1980/7231048/b047f8117130/micromachines-11-00380-g009.jpg
https://cdn.ncbi.nlm.nih.gov/pmc/blobs/1980/7231048/b23ca4114baa/micromachines-11-00380-g010.jpg
https://cdn.ncbi.nlm.nih.gov/pmc/blobs/1980/7231048/45dcde2f69ba/micromachines-11-00380-g011.jpg
https://cdn.ncbi.nlm.nih.gov/pmc/blobs/1980/7231048/3ddbd639ec95/micromachines-11-00380-g012.jpg
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