Surface defects in ultrasonic vibration assisted cutting of TiCp/TC4 with PCD tool
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摘要:
研究微观角度下PCD刀具超声振动辅助切削TiCp/TC4时，超声振动对材料表面缺陷的影响。基于ABAQUS/Explicit有限元软件，建立PTMCs二维切削微观非均质模型，开展不同体积分数下的多颗粒切削仿真；并采用仿真和实验相结合的方法，分析切削速度对切削温度变化的影响规律，阐述TiCp/TC4在切削过程中的颗粒受力破碎过程，讨论同体积分数的TiCp/TC4切削表面缺陷的表现形式。结果表明：超声振动切削时，切削温度始终较低，TiCp/TC4表面缺陷表现形式多为颗粒切断和颗粒突起；且超声振动能有效阻断颗粒与基体间的应力持续传递，使应力优先在颗粒间传递，减小了基体变形，促使颗粒破碎，提升材料表面加工质量，同时验证实验结果与仿真结果相符。
Abstract:To investigate the microscopic influence of ultrasonic vibration on the surface flaws of particle-reinforced titanium matrix composites TiCp/TC4 during cutting with ultrasonic vibration of PCD tools. A two-dimensional cutting microscopic non-homogeneous model for TiCp/TC4 was established using ABAQUS/Explicit finite element software, and different volume fractions of the multi-particle cutting simulation were performed to analyze the changing rule of cutting speed on cutting temperature using a combination of simulation and experimental methods, to elaborate the particle force crushing process of PTMCs during the cutting process, and to discuss the defect manifestation. The results show that ultrasonic vibration cutting, the cutting temperature is always lower, the surface defects are mostly particle cut off and particle protrusion, and ultrasonic vibration can effectively block the stress between the particle and the substrate continues to transfer, so that the stress is prioritized in the transmission between the particles, reducing substrate deformation, prompting the particles to break first, and improving the surface. The experimental results were validated to be consistent with the simulation results.
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Key words:
- titanium matrix composites /
- ultrasonic vibration /
- PCD tool /
- finite element simulation
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图 2 VMC850B加工中心及场发射扫描电子显微镜
Figure 2. VMC850B machining center and field emission scanning electron microscope
图 4 超声振动切削与传统切削温度信号变化曲线
Figure 4. Ultrasonic vibration cutting and traditional cutting temperature signal change curve
图 6 切削速度对切削温度影响的对比验证
Figure 6. Comparative verification of the effect of cutting speed on cutting temperature
图 7 颗粒体积分数为8% TiCp/TC4的已加工表面
Figure 7. Finished surface of particle volume fraction 8% TiCp/TC4
图 10 颗粒体积分数为15%TiCp/TC4的已加工表面
Figure 10. Finished surface of particle volume fraction 15%PTiCp/TC4
图 11 不同切削速度下的TiCp/TC4表面形貌
Figure 11. Surface morphologies of TiCp/TC4 with different cutting speeds
图 15 仿真中颗粒应力及颗粒团簇SEM图片
Figure 15. SEM images of particle stress and particle clusters in simulation
表 1 工件材料的性能参数
Table 1. Performance parameters of the workpiece material
材料性能 TC4 TiC 密度ρ / (kg·m−3) 4510 4390 泊松比 μ 0.34 0.18 弹性模量 E / GPa 110 470 导热系数 k / [W·(m·K)−1] 5.708 17.200 比热容 c / [J·(kg·K)−1] 457.2 568.0 
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表 2 切削参数
Table 2. Cutting parameters
切削参数 数值 切削速度 vs / (m·min−1) 100 每齿进给量 f1 / (mm·z−1) 0.08 切削深度 ap / mm 3 振幅 A / μm 3 超声频率 f / kHz 20
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