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纳米金刚石涂层刀具高速铣削7075铝合金的工艺参数优化

邵伟平 张韬

邵伟平, 张韬. 纳米金刚石涂层刀具高速铣削7075铝合金的工艺参数优化[J]. 金刚石与磨料磨具工程, 2022, 42(4): 473-480. doi: 10.13394/j.cnki.jgszz.2021.4003
引用本文: 邵伟平, 张韬. 纳米金刚石涂层刀具高速铣削7075铝合金的工艺参数优化[J]. 金刚石与磨料磨具工程, 2022, 42(4): 473-480. doi: 10.13394/j.cnki.jgszz.2021.4003
SHAO Weiping, ZHANG Tao. Process parameters optimization of high-speed milling 7075 aluminum alloy with nano-diamond coated tool[J]. Diamond & Abrasives Engineering, 2022, 42(4): 473-480. doi: 10.13394/j.cnki.jgszz.2021.4003
Citation: SHAO Weiping, ZHANG Tao. Process parameters optimization of high-speed milling 7075 aluminum alloy with nano-diamond coated tool[J]. Diamond & Abrasives Engineering, 2022, 42(4): 473-480. doi: 10.13394/j.cnki.jgszz.2021.4003

纳米金刚石涂层刀具高速铣削7075铝合金的工艺参数优化

doi: 10.13394/j.cnki.jgszz.2021.4003
基金项目: 江苏省自然科学基金(BK20201142)。
详细信息
    作者简介:

    邵伟平,男,1973年生,高级实验师。主要研究方向:数控技术与切削加工。E-mail:swp523@sina.com

    通讯作者:

    张韬,女,1984年生,博士、副教授。主要研究方向:CVD金刚石的制备及应用。E-mail:zhangt@wxit.edu.cn

  • 中图分类号: TG58; TH145.9

Process parameters optimization of high-speed milling 7075 aluminum alloy with nano-diamond coated tool

  • 摘要: 采用热丝CVD法制备纳米金刚石薄膜涂层刀具,利用场发射扫描电子显微镜表征薄膜的表面形貌,并用已制备的CVD金刚石涂层刀具,在无润滑干切条件下高速铣削7075铝合金工件,对其精铣工艺参数进行单因素及正交试验,探索精铣后工件的表面粗糙度变化规律并进行工艺参数优化。结果表明:随着主轴转速n从5000 r/min提高到8000 r/min, 工件平均表面粗糙度在逐级缓慢降低;当进给速度vf在1000~7000 mm/min范围内,随着vf提高工件平均表面粗糙度快速增大,在vf为7000 mm/min时,其值达1.790 μm;当轴向切削深度ap在0.1~0.4 mm范围内,随着ap提高,工件平均表面粗糙度逐步增大,但ap在0.2 mm之后其增大趋势变缓。对7075铝合金工件精铣表面粗糙度影响最大的是vf,其次为nap的影响最弱;其精铣的最优参数组合是ap=0.2 mm、vf=1 000 mm/min、n=8 000 r/min,精铣后的表面粗糙度平均值为0.516 μm。选用纳米金刚石薄膜涂层刀具精铣7075铝合金时,为得到较低的表面粗糙度,应选择高主轴转速、低进给速度、合适的轴向切削深度。

     

  • 图  1  纳米金刚石薄膜涂层刀具制备过程中的表面形貌

    Figure  1.  Surface topography of nano-diamond film coated tool during preparation

    图  2  纳米金刚石薄膜涂层铣刀形貌

    Figure  2.  Morphology of milling cutter coated with nano-diamond film

    图  3  正交试验的工件表面形貌

    Figure  3.  Workpiece surface morphology by orthogonal test

    表  1  金刚石薄膜形核及生长参数

    Table  1.   Nucleation and growth parameters of diamond films

    参数取值
    形核生长
    CH4与H2的流量比 Q / (mL·mL−1)1∶50 1 ∶50
    气压 p / kPa1.52.0
    基体温度 θs / °C800900
    热丝温度 θr / °C2 000±2002 200±200
    沉积时间 t1 / min30300
    下载: 导出CSV

    表  2  正交试验因素水平表

    Table  2.   Factor level table of orthogonal test

    水平因素
    轴向切削深度
    ap / mm
    A
    进给速度
    vf / (mm·min−1)
    B
    主轴转速
    n / (r·min−1)
    C
    10.11 0006 000
    20.25 0007 000
    30.47 0008 000
    下载: 导出CSV

    表  3  主轴转速对工件表面粗糙度的影响

    Table  3.   Influences of spindle speeds on workpiece surface roughness

    序号主轴转速
    n / (r·min−1)
    表面粗糙度
    Ra / μm
    表面粗糙度平均值
    $\overline R_{\mathrm{a} }$ /μm
    15 0000.826,1.489,0.882,0.690,0.9140.960
    26 0000.895,0.709,0.923,0.827,0.7280.816
    37 0000.469,0.771,0.582,0.938,0.5990.672
    48 0000.474,0.532,0.647,0.607,0.6280.578
    下载: 导出CSV

    表  4  进给速度对工件表面粗糙度的影响

    Table  4.   Influences of feed speeds on workpiece surface roughness

    序号进给速度
    vf / (mm·min−1)
    表面粗糙度
    Ra /
    μm
    表面粗糙度
    平均值
    $\overline R_{\mathrm{a} }$ /
    μm
    11 0000.575,0.324,0.638,0.587,0.5280.530
    23 0000.986,0.862,0.690,1.131,0.8450.903
    35 0001.081,1.575,1.441,2.023,1.2501.474
    47 0001.639,1.524,1.597,2.184,2.0061.790
    下载: 导出CSV

    表  5  轴向切削深度对工件表面粗糙度的影响

    Table  5.   Influences of axial cutting depths on workpiece surface roughness

    序号轴向切削深度
    ap / mm
    表面粗糙度
    Ra /μm
    表面粗糙度
    平均值
    $\overline R_{\mathrm{a}} $ /μm
    10.10.562,0.765,0.479,0.625,0.3560.557
    20.20.895,0.709,0.923,0.827,0.7280.816
    30.31.018,0.846,0.871,0.823,0.9200.896
    40.40.976,0.832,0.936,0.978,1.1880.982
    下载: 导出CSV

    表  6  正交试验组合及结果

    Table  6.   Orthogonal test combinations and results

    试验组号参数组合表面粗糙度
    Ra /μm
    表面粗糙度
    平均值
    $\overline R _{\mathrm{a}} $ / μm
    1#A1B1C10.820,0.867,0.569,0.762,0.8000.764
    2#A1B2C20.989,1.079,1.307,1.890,2.3931.532
    3#A1B3C31.693,0.866,1.589,2.191,0.8311.434
    4#A2B1C20.575,0.322,0.638,0.587,0.5270.530
    5#A2B2C31.008,1.023,0.735,0.937,1.1170.964
    6#A2B3C11.747,1.167,1.652,2.944,2.2801.958
    7#A3B1C31.005,0.383,0.430,0.502,0.7040.605
    8#A3B2C11.754,1.585,1.566,1.884,1.7761.713
    9#A3B3C21.615,1.933,2.180,2.096,2.4112.047
    下载: 导出CSV

    表  7  3因素的工件表面粗糙度均值以及极差R

    Table  7.   Average values of workpiece surface roughness and range R values of 3 factors

    项目取值
    ap / mmvf / (mm·min−1)n / (r·min−1)
    均值t11.2430.6331.478
    均值t21.1511.4031.370
    均值t31.4551.8131.001
    极差R0.3041.1800.477
    下载: 导出CSV
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  • 收稿日期:  2021-12-07
  • 修回日期:  2022-05-30
  • 刊出日期:  2022-08-16

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