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航空航天铝合金构件装配孔钻削出口毛刺研究进展

王笑时 杨国林 董志刚 康仁科

王笑时, 杨国林, 董志刚, 康仁科. 航空航天铝合金构件装配孔钻削出口毛刺研究进展[J]. 金刚石与磨料磨具工程, 2022, 42(4): 385-409. doi: 10.13394/j.cnki.jgszz.2021.0095
引用本文: 王笑时, 杨国林, 董志刚, 康仁科. 航空航天铝合金构件装配孔钻削出口毛刺研究进展[J]. 金刚石与磨料磨具工程, 2022, 42(4): 385-409. doi: 10.13394/j.cnki.jgszz.2021.0095
WANG Xiaoshi, YANG Guolin, DONG Zhigang, KANG Renke. Research progress on exit burr in drilling assembly hole of aerospace aluminum alloy components[J]. Diamond & Abrasives Engineering, 2022, 42(4): 385-409. doi: 10.13394/j.cnki.jgszz.2021.0095
Citation: WANG Xiaoshi, YANG Guolin, DONG Zhigang, KANG Renke. Research progress on exit burr in drilling assembly hole of aerospace aluminum alloy components[J]. Diamond & Abrasives Engineering, 2022, 42(4): 385-409. doi: 10.13394/j.cnki.jgszz.2021.0095

航空航天铝合金构件装配孔钻削出口毛刺研究进展

doi: 10.13394/j.cnki.jgszz.2021.0095
详细信息
    作者简介:

    王笑时,男,1997年生。主要研究方向:精密加工技术与设备。E-mail: wangxs0102@163.com

    通讯作者:

    康仁科,男,1962 年生,教授。主要研究方向:精密与超精密加工、特种加工等。E-mail:kangrk@dlut.edu.cn

  • 中图分类号: TG58; TG52; F416.41

Research progress on exit burr in drilling assembly hole of aerospace aluminum alloy components

  • 摘要: 航空航天制造业中存在大量的铝合金装配孔加工需求。装配孔主要通过钻削加工实现,加工中存在铝合金出口毛刺过大的问题。出口毛刺直接影响工件的精度、抗疲劳强度、装配性能,去毛刺工序会极大地增加工时和成本。因此有必要对铝合金装配孔钻削出口毛刺进行研究,实现对出口毛刺的控制。从铝合金钻削出口毛刺的类型和测量方法、形成机理和高度预测以及毛刺控制方法等方面进行了系统性的论述,以期为铝合金钻削加工出口毛刺的研究提供帮助。

     

  • 图  1  铝合金钻削典型出口毛刺[9]

    Figure  1.  Typical exit burr of aluminum alloy drilling[9]

    图  2  出口毛刺类型[6]

    Figure  2.  Exit burr type[6]

    图  3  毛刺形态试验结果[21]

    Figure  3.  Burr shape results[21]

    图  4  出口毛刺形态[25]

    Figure  4.  Exit burr shape[25]

    图  5  出口毛刺类型和形态[27]

    Figure  5.  Exit burr type and shape[27]

    图  6  毛刺形状和主要特征参数[6]

    Figure  6.  Burr shape and main characteristic parameters[6]

    图  7  毛刺几何形状特征[28]

    Figure  7.  Geometric characteristics of burrs[28]

    图  8  使用光学CMM测量毛刺特征[28]

    Figure  8.  Measurement of burr characteristics using optical CMM[28]

    图  9  形状激光显微镜及测量结果[33]

    Figure  9.  Shape laser microscope and measurement results[33]

    图  10  基于激光三角测量系统的毛刺非接触测量[15]

    Figure  10.  Non contact measurement of burr based on laser triangulation system[15]

    图  11  线激光毛刺测量装置[35]

    Figure  11.  Line laser burr measuring device[35]

    图  12  出口毛刺形成过程[8]

    Figure  12.  Formation process of exit burr[8]

    图  13  出口毛刺有限元仿真结果[47]

    Figure  13.  Finite element simulation results of exit burr[47]

    图  14  层间间隙与层间毛刺关系[57]

    Figure  14.  Relationship between interlayer gap and interlayer burr[57]

    图  15  预紧力与层间毛刺高度间关系[57]

    Figure  15.  Relationship between preload and interlayer burr height[57]

    图  16  模拟值与实测值结果[62]

    Figure  16.  Simulated and measured results[62]

    图  17  毛刺高度的试验结果和预测结果的比较[55]

    Figure  17.  Comparison of the experimental and predicted results for the burr height[55]

    图  18  出口毛刺高度与切削参数间关系[69]

    Figure  18.  Relationship between exit burr height and cutting parameters[69]

    图  19  不同参数下出口毛刺情况[27]

    Figure  19.  Exit burr under different parameters[27]

    图  20  不同刀具参数、加工参数下铝合金出口毛刺形态[63]

    Figure  20.  Exit burr morphology of aluminum alloy under different tool parameters and machining parameters[63]

    图  21  麻花钻结构 [78]

    Figure  21.  Twist drill structure[78]

    图  22  3种抑制出口毛刺的结构[79]

    Figure  22.  Three structures for suppressing outlet burr[79]

    图  23  修改钻头结构 (l3=2 mm,k2=2°)[81]

    Figure  23.  Modified drill (l3=2 mm,k2=2°)[81]

    图  24  刀具优化前后毛刺高度对比[81]

    Figure  24.  Comparison of burr height before and aftertool optimization[81]

    图  25  钻头刃型[86]

    Figure  25.  Bit edge type[86]

    图  26  研制钻头[86]

    Figure  26.  Development bits[86]

    图  27  不同刀具产生毛刺对比[86]

    Figure  27.  Comparison of burr produced by different cutting tools[86]

    图  28  刀具结构[87]

    Figure  28.  Tool structure[87]

    图  29  试验刀具[87]

    Figure  29.  Test tool[87]

    图  30  试验结果[87]

    Figure  30.  Experimental result[87]

    图  31  刀具结构[88]

    Figure  31.  Tool structure[88]

    图  32  研制阶梯钻[90]

    Figure  32.  Development of step drill[90]

    图  33  振动制孔原理[98]

    Figure  33.  Principle of ultrasonic vibration drilling[98]

    图  34  超声振动钻孔原理图[42]

    Figure  34.  Schematic diagram of ultrasonic vibration drilling[42]

    图  35  不同切削参数下超声振动钻削和普通钻削毛刺高度对比[33]

    Figure  35.  Burr height of ultrasonic vibration drilling and ordinary drilling under different cutting parameters[33]

    图  36  超声刀柄和超声电源[8]

    Figure  36.  Ultrasonic tool holder and ultrasonic power supply[8]

    图  37  旋转超声钻削和普通钻削下毛刺高度对比[8]

    Figure  37.  Comparison of drilling burr height between rotary ultrasonic drilling and general drilling[8]

    图  38  普通钻削与低频钻削出口毛刺对比[64]

    Figure  38.  Comparison of outlet burr between ordinary drilling and low frequency drilling[64]

    图  39  振动辅助加工[64]

    Figure  39.  Vibration-assisted machining [64]

    图  40  振动钻削出口毛刺高度[97]

    Figure  40.  Vibration drilling exit burr height[97]

    图  41  低温钻削试验装置[102]

    Figure  41.  Cryogenic cooling drilling experimental setup[102]

    图  42  压紧力对出口毛刺高度影响[44]

    Figure  42.  Influence of pressing force on exit burr height[44]

    图  43  可调预压紧力钻孔系统[106]

    Figure  43.  Adjustable preload drilling system[106]

    图  44  不同压紧力下毛刺形貌[106]

    Figure  44.  Burr morphology under different pressing forces[106]

    表  1  毛刺高度预测研究进展

    Table  1.   Research progress of burr height prediction

    研究学者预测方法预测结果
    吴丹等[58]试验获得轴向力经验公式,有限元法预测毛刺生成初始位置,能量法建立毛刺高度理论模型误差<30%
    胡力闯等[59]试验建立钻削力经验公式,结合经典薄板弯曲理论和能量法建模,考虑钻孔位置对工件刚性和毛刺高度的影响误差<13%
    WANG等[61]轴向定位法获得了内、外切削点,确定工作角度、切削力等参数,根据形成机理进行理论建模误差1.96%
    CHANG等[62]只有切削力的正向部分和工件的弹性变形回弹有助于毛刺的形成,由此建立切削力模型和毛刺高度模型误差<10%
    MANDRA等[54]将钻削轴向力与刀具磨损引起的摩擦力相结合,建立了基于的受力模型,利用力做功与材料变形之间的能量平衡建模误差<30%
    LI等[64]基于毛刺形成的机理、材料的变形机制、运动学模型以及受力分析建立毛刺高度模型误差<8%
    周越等[66]引入BN和正则化技术,提高训练效率精度,基于蚁群算法的启发式整体调优算法,完成模型的全局优化,预测毛刺高度误差9.34%
    GÖKÇE等[55]使用试验数据预测响应,使用神经拟合工具评估实验数据,使用前馈−反向传播执行ANN模型预测成功率为99.6%
    鲁琦渊[33]由试验结果,根据最小二乘法,拟合出毛刺高度回归方程误差15.76%
    ABDELHAFEEZ等[69]由响应曲面法建立毛刺高度拟合方程,并分析各参数显著性实测值、预测值吻合较好
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  • 收稿日期:  2021-12-27
  • 修回日期:  2022-03-25
  • 录用日期:  2022-03-30
  • 网络出版日期:  2023-02-07
  • 刊出日期:  2022-08-10

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