纤维方向对碳纤维复合材料切削加工影响综述
|
摘要
碳纤维增强复合材料因其具有高强度、耐高温、耐辐射、抗化学腐蚀等特性,广泛应用于航空航天、交通运输、运动器材等方面。但该材料的非均匀性以及各向异性导致其在不同纤维方向角下呈现出不同的加工特性,对实际生产过程中的切削刀具寿命和工件质量等都有很大影响。基于碳纤维增强复合材料的纤维方向,综述其对切削加工过程中切屑形成机理、切削力、切削温度、刀具磨损以及加工表面质量的影响情况,并探讨了未来的研究趋势。
Carbon fiber reinforced plastics are widely used in aerospace,transportation,sports equipment and other fields due to their high strength,high temperature resistance,radiation resistance and chemical corrosion resistance. Due to the inhomogeneity and anisotropy of the material,the processing characteristics are different at different fiber orientation angles,which have great influence on the service life of cutting tools and the quality of workpieces. This paper reviews the effect of the fiber orientation of carbon fiber reinforced plastics on the mechanism of chip formation,cutting force,cutting temperature,tool wear,and machined surface quality during the cutting process and discusses the future research and development trends.
Carbon fiber reinforced plastics are widely used in aerospace,transportation,sports equipment and other fields due to their high strength,high temperature resistance,radiation resistance and chemical corrosion resistance. Due to the inhomogeneity and anisotropy of the material,the processing characteristics are different at different fiber orientation angles,which have great influence on the service life of cutting tools and the quality of workpieces. This paper reviews the effect of the fiber orientation of carbon fiber reinforced plastics on the mechanism of chip formation,cutting force,cutting temperature,tool wear,and machined surface quality during the cutting process and discusses the future research and development trends.
引文
[1]简龙艺,林有希.碳纤维复合材料铣削加工研究进展[J].工具技术,2014,48(4):3-6.
[2]Wang X M,Zhang L C. An experimental investigation into the orthogonal cutting of unidirectional fibre reinforced plastics[J]. International Journal of Machine Tools&Manufacture,2003,43(10):1015-1022.
[3]Ucar M,Wang Y. End-milling machinability of a carbon fiber reinforced laminated composite[J]. Journal of Advanced MaterialsCovina-,2005,37(4):46-52.
[4]Koplev A. Cutting of cfrp with single edge tools[M].[S. I.]:Advances in Composite Materials,1980.
[5]Pwu H Y,Hocheng H. Chip formation model of cutting fiber-reinforced plastics perpendicular to fiber axis[J]. Journal of Manufacturing Science&Engineering,1998,120(1):192-196.
[6]Davim,J. P.复合材料加工技术[M].安庆龙,译.北京:国防工业出版社,2016.
[7]蔡晓江.基于复合材料各向异性的切削力热变化规律和表面质量评价试验研究[D].上海:上海交通大学,2014.
[8]Bhatnagar N,Ramakrishnan N,Naik N K,et al. On the machining of fiber reinforced plastic(FRP)composite laminates[J].International Journal of Machine Tools&Manufacture,1995,35(5):701-716.
[9]Sreejith P S,Krishnamurthy R,Malhotra S K,et al. Evaluation of PCD tool performance during machining of carbon/phenolic ablative composites[J]. Journal of Materials Processing Tech,2000,104(1):53-58.
[10] Wang D H,Ramulu M,Arola D. Orthogonal cutting mechanisms of graphite/epoxy composite. Part I:unidirectional laminate[J]. International Journal of Machine Tools&Manufacture,1995,35(12):1623-1638.
[11]张厚江,陈五一,陈鼎昌.碳纤维复合材料切削机理的研究[J].航空制造技术,2004(7):57-59.
[12]Harris B,Metals I O. Engineering Composite Materials[M].[S.I]:Institute of Materials Minerals&Mining,1999.
[13]Everstine G C,Rogers T G. A Theory of Machining of FiberReinforced Materials[J]. Journal of Composite Materials,1971,5(1):94-106.
[14]Arola D,Ramulu M. Orthogonal cutting of fiber-reinforced composites:A finite element analysis[J]. International Journal of Mechanical Sciences,1997,39(5):597-613.
[15]Yigit Karpat,Naki Polat. Mechanistic force modeling for milling of carbon fiber reinforced polymers with double helix tools[J].CIRP Annals-Manufacturing Technology,2013,62(1):95-98.
[16]张厚江.单向碳纤维复合材料直角自由切削力的研究[J].航空学报,2005,26(5):604-609.
[17]Zhang L C,Zhang H J,Wang X M. A Force prediction model for cutting unidirectional fibre-reinforced plastics[J]. Machining Science&Technology,2001,5(3):293-305.
[18] Xu W,Zhang L C. On the mechanics and material removal mechanisms of vibration-assisted cutting of unidirectional fibrereinforced polymer composites[J]. International Journal of Machine Tools&Manufacture,2014,80/81(5):1-10.
[19]Rao G V G,Mahajan P,Bhatnagar N. Three-dimensional macro-mechanical finite element model for machining of unidirectional-fiber reinforced polymer composites[J]. Materials Science&Engineering A,2008,498(1):142-149.
[20]Hocheng H,Puw H Y,Huang Y. Preliminary study on milling of unidirectional carbon fiberreinforced plastics[J]. Composites Manufacturing,1993,4(2):103-108.
[21]龚佑宏,韩舒,杨霓虹,等.纤维方向对碳纤维复合材料加工性能的影响[J].航空制造技术,2013,443(23-24):137-140.
[22]贺福.碳纤维及其应用技术[M].北京:化学工业出版社,2004.
[23]沈观林,胡更开.复合材料力学[M].北京:清华大学出版社,2006.
[24]Brinksmeier E,Fangmann S,Rentsch R. Drilling of composites and resulting surface integrity[J]. CIRP Annals-Manufacturing Technology,2011,60(1):57-60.
[25]朱国平.单向C/E复合材料钻削温度场研究[D].大连:大连理工大学,2013.
[26]Sreejith P S,Krishnamurthy R,Malhotra S K,et al. Evaluation of PCD tool performance during machining of carbon/phenolic ablative composites[J]. Journal of Materials Processing Tech,2000,104(1):53-58.
[27]R Zitoune,F Collombet,F Lachaud,et al.Experiment-calculation comparison of the cutting conditions representative of the long fiber composite drilling phase[J]. Composites Science&Technology,2005,65(3):455-466.
[28]鲍永杰. C/E复合材料制孔缺陷成因与高效制孔技术[D].大连:大连理工大学,2010.
[29]蔡晓江,邱坤贤,王呈栋,等.航空高强度碳纤维单向层合结构复合材料在切削过程中的各向异性行为研究[J].南京航空航天大学学报,2014,46(5):684-693.
[30]Rawat S,Attia H. Wear mechanisms and tool life management of WC-Co drills during dry high speed drilling of woven carbon fibre composites[J]. Wear,2009,267(5/6/7/8):1022-1030.
[31]花崎,伸作,藤原,等. CFRP切削における工具摩耗機構[J].日本機械学会論文集C編,1994,60:297-302.
[32]Boothroyd G,Knight W A. Fundamentals of Metal Machining and Machine Tool[J]. Fire Safety Journal,1988,25(2):171-173.
[33]林有希,禹杰,林华.碳纤维/树脂基复合材料高速铣削的刀具磨损机理[J].中国表面工程,2016,29(5):138-145.
[34]Usui S,Wadell J,Marusich T. Finite Element Modeling of Carbon Fiber Composite Orthogonal Cutting and Drilling☆[J].Procedia Cirp,2014,14(14):211-216.
[35] Dold C,Henerichs M,Bochmann L,et al. Comparison of Ground and Laser Machined Polycrystalline Diamond(PCD)Tools in Cutting Carbon Fiber Reinforced Plastics(CFRP)for Aircraft Structures[J]. Procedia Cirp,2012,1(7):178-183.
[36]Hosokawa A,Hirose N,Ueda T,et al. High-quality machining of CFRP with high helix end mill[J]. CIRP Annals-Manufacturing Technology,2014,63(1):89-92.
[37]王志超,林有希,林华.高速铣削CFRP单向层合板的刀具磨损研究[J].兵器材料科学与工程,2017,40(5):77-81.
[38]Nakasuji T,Kodera S,Hara S,et al. Diamond Turning of Brittle Materials for Optical Components[J]. CIRP Annals-Manufacturing Technology,1990,39(1):89-92.
[39]Geis T,Klingelholler C,Hintze W. Constant Depth Scoring of Fibre Reinforced Plastic Structures to Prevent Delamination[J].Procedia Cirp,2014,14:205-210.
[40]Koplev A,Lystrup A,Vorm T. The cutting process,chips,and cutting forces in machining CFRP[J]. Composites,1983,14(4):371-376.
[41]Wern C W,Ramulu M,Shukla A. Investigation of stresses in he orthogonal cutting of fiber-reinforced plastics[J]. Experimental Mechanics,1996,36(1):33-41.
[42]Wang X M,Zhang L C. An experimental investigation into the orthogonal cutting of unidirectional fibre reinforced plastics[J].International Journal of Machine Tools&Manufacture,2003,43(10):1015-1022.
[43]El-Hofy M H,Soo S L,Aspinwall D K,et al. Factors Affecting Workpiece Surface Integrity in Slotting of CFRP[J]. Procedia Engineering,2011,19(1):94-99.
[2]Wang X M,Zhang L C. An experimental investigation into the orthogonal cutting of unidirectional fibre reinforced plastics[J]. International Journal of Machine Tools&Manufacture,2003,43(10):1015-1022.
[3]Ucar M,Wang Y. End-milling machinability of a carbon fiber reinforced laminated composite[J]. Journal of Advanced MaterialsCovina-,2005,37(4):46-52.
[4]Koplev A. Cutting of cfrp with single edge tools[M].[S. I.]:Advances in Composite Materials,1980.
[5]Pwu H Y,Hocheng H. Chip formation model of cutting fiber-reinforced plastics perpendicular to fiber axis[J]. Journal of Manufacturing Science&Engineering,1998,120(1):192-196.
[6]Davim,J. P.复合材料加工技术[M].安庆龙,译.北京:国防工业出版社,2016.
[7]蔡晓江.基于复合材料各向异性的切削力热变化规律和表面质量评价试验研究[D].上海:上海交通大学,2014.
[8]Bhatnagar N,Ramakrishnan N,Naik N K,et al. On the machining of fiber reinforced plastic(FRP)composite laminates[J].International Journal of Machine Tools&Manufacture,1995,35(5):701-716.
[9]Sreejith P S,Krishnamurthy R,Malhotra S K,et al. Evaluation of PCD tool performance during machining of carbon/phenolic ablative composites[J]. Journal of Materials Processing Tech,2000,104(1):53-58.
[10] Wang D H,Ramulu M,Arola D. Orthogonal cutting mechanisms of graphite/epoxy composite. Part I:unidirectional laminate[J]. International Journal of Machine Tools&Manufacture,1995,35(12):1623-1638.
[11]张厚江,陈五一,陈鼎昌.碳纤维复合材料切削机理的研究[J].航空制造技术,2004(7):57-59.
[12]Harris B,Metals I O. Engineering Composite Materials[M].[S.I]:Institute of Materials Minerals&Mining,1999.
[13]Everstine G C,Rogers T G. A Theory of Machining of FiberReinforced Materials[J]. Journal of Composite Materials,1971,5(1):94-106.
[14]Arola D,Ramulu M. Orthogonal cutting of fiber-reinforced composites:A finite element analysis[J]. International Journal of Mechanical Sciences,1997,39(5):597-613.
[15]Yigit Karpat,Naki Polat. Mechanistic force modeling for milling of carbon fiber reinforced polymers with double helix tools[J].CIRP Annals-Manufacturing Technology,2013,62(1):95-98.
[16]张厚江.单向碳纤维复合材料直角自由切削力的研究[J].航空学报,2005,26(5):604-609.
[17]Zhang L C,Zhang H J,Wang X M. A Force prediction model for cutting unidirectional fibre-reinforced plastics[J]. Machining Science&Technology,2001,5(3):293-305.
[18] Xu W,Zhang L C. On the mechanics and material removal mechanisms of vibration-assisted cutting of unidirectional fibrereinforced polymer composites[J]. International Journal of Machine Tools&Manufacture,2014,80/81(5):1-10.
[19]Rao G V G,Mahajan P,Bhatnagar N. Three-dimensional macro-mechanical finite element model for machining of unidirectional-fiber reinforced polymer composites[J]. Materials Science&Engineering A,2008,498(1):142-149.
[20]Hocheng H,Puw H Y,Huang Y. Preliminary study on milling of unidirectional carbon fiberreinforced plastics[J]. Composites Manufacturing,1993,4(2):103-108.
[21]龚佑宏,韩舒,杨霓虹,等.纤维方向对碳纤维复合材料加工性能的影响[J].航空制造技术,2013,443(23-24):137-140.
[22]贺福.碳纤维及其应用技术[M].北京:化学工业出版社,2004.
[23]沈观林,胡更开.复合材料力学[M].北京:清华大学出版社,2006.
[24]Brinksmeier E,Fangmann S,Rentsch R. Drilling of composites and resulting surface integrity[J]. CIRP Annals-Manufacturing Technology,2011,60(1):57-60.
[25]朱国平.单向C/E复合材料钻削温度场研究[D].大连:大连理工大学,2013.
[26]Sreejith P S,Krishnamurthy R,Malhotra S K,et al. Evaluation of PCD tool performance during machining of carbon/phenolic ablative composites[J]. Journal of Materials Processing Tech,2000,104(1):53-58.
[27]R Zitoune,F Collombet,F Lachaud,et al.Experiment-calculation comparison of the cutting conditions representative of the long fiber composite drilling phase[J]. Composites Science&Technology,2005,65(3):455-466.
[28]鲍永杰. C/E复合材料制孔缺陷成因与高效制孔技术[D].大连:大连理工大学,2010.
[29]蔡晓江,邱坤贤,王呈栋,等.航空高强度碳纤维单向层合结构复合材料在切削过程中的各向异性行为研究[J].南京航空航天大学学报,2014,46(5):684-693.
[30]Rawat S,Attia H. Wear mechanisms and tool life management of WC-Co drills during dry high speed drilling of woven carbon fibre composites[J]. Wear,2009,267(5/6/7/8):1022-1030.
[31]花崎,伸作,藤原,等. CFRP切削における工具摩耗機構[J].日本機械学会論文集C編,1994,60:297-302.
[32]Boothroyd G,Knight W A. Fundamentals of Metal Machining and Machine Tool[J]. Fire Safety Journal,1988,25(2):171-173.
[33]林有希,禹杰,林华.碳纤维/树脂基复合材料高速铣削的刀具磨损机理[J].中国表面工程,2016,29(5):138-145.
[34]Usui S,Wadell J,Marusich T. Finite Element Modeling of Carbon Fiber Composite Orthogonal Cutting and Drilling☆[J].Procedia Cirp,2014,14(14):211-216.
[35] Dold C,Henerichs M,Bochmann L,et al. Comparison of Ground and Laser Machined Polycrystalline Diamond(PCD)Tools in Cutting Carbon Fiber Reinforced Plastics(CFRP)for Aircraft Structures[J]. Procedia Cirp,2012,1(7):178-183.
[36]Hosokawa A,Hirose N,Ueda T,et al. High-quality machining of CFRP with high helix end mill[J]. CIRP Annals-Manufacturing Technology,2014,63(1):89-92.
[37]王志超,林有希,林华.高速铣削CFRP单向层合板的刀具磨损研究[J].兵器材料科学与工程,2017,40(5):77-81.
[38]Nakasuji T,Kodera S,Hara S,et al. Diamond Turning of Brittle Materials for Optical Components[J]. CIRP Annals-Manufacturing Technology,1990,39(1):89-92.
[39]Geis T,Klingelholler C,Hintze W. Constant Depth Scoring of Fibre Reinforced Plastic Structures to Prevent Delamination[J].Procedia Cirp,2014,14:205-210.
[40]Koplev A,Lystrup A,Vorm T. The cutting process,chips,and cutting forces in machining CFRP[J]. Composites,1983,14(4):371-376.
[41]Wern C W,Ramulu M,Shukla A. Investigation of stresses in he orthogonal cutting of fiber-reinforced plastics[J]. Experimental Mechanics,1996,36(1):33-41.
[42]Wang X M,Zhang L C. An experimental investigation into the orthogonal cutting of unidirectional fibre reinforced plastics[J].International Journal of Machine Tools&Manufacture,2003,43(10):1015-1022.
[43]El-Hofy M H,Soo S L,Aspinwall D K,et al. Factors Affecting Workpiece Surface Integrity in Slotting of CFRP[J]. Procedia Engineering,2011,19(1):94-99.