CN117556645B - Surface roughness Sz-based composite member profile milling parameter determination method - Google Patents
Surface roughness Sz-based composite member profile milling parameter determination method Download PDFInfo
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- 230000003746 surface roughness Effects 0.000 title claims abstract description 57
- 238000003801 milling Methods 0.000 title claims abstract description 44
- 239000002131 composite material Substances 0.000 title claims abstract description 39
- 238000000034 method Methods 0.000 title claims abstract description 33
- 238000005520 cutting process Methods 0.000 claims abstract description 71
- 238000003754 machining Methods 0.000 claims abstract description 35
- VNWKTOKETHGBQD-UHFFFAOYSA-N methane Chemical compound C VNWKTOKETHGBQD-UHFFFAOYSA-N 0.000 claims abstract description 22
- 229920000049 Carbon (fiber) Polymers 0.000 claims abstract description 21
- 239000004917 carbon fiber Substances 0.000 claims abstract description 21
- 238000012545 processing Methods 0.000 claims abstract description 19
- 230000005284 excitation Effects 0.000 claims description 6
- 238000004088 simulation Methods 0.000 claims description 3
- 238000012360 testing method Methods 0.000 description 8
- 239000000463 material Substances 0.000 description 4
- 238000010586 diagram Methods 0.000 description 3
- 238000007796 conventional method Methods 0.000 description 2
- 230000007547 defect Effects 0.000 description 2
- 239000000835 fiber Substances 0.000 description 2
- 239000011159 matrix material Substances 0.000 description 2
- 238000012986 modification Methods 0.000 description 2
- 230000004048 modification Effects 0.000 description 2
- 230000009286 beneficial effect Effects 0.000 description 1
- 238000010276 construction Methods 0.000 description 1
- 230000007797 corrosion Effects 0.000 description 1
- 238000005260 corrosion Methods 0.000 description 1
- 230000000694 effects Effects 0.000 description 1
- 238000011156 evaluation Methods 0.000 description 1
- 238000004519 manufacturing process Methods 0.000 description 1
- 230000003340 mental effect Effects 0.000 description 1
- 239000011347 resin Substances 0.000 description 1
- 229920005989 resin Polymers 0.000 description 1
- 238000012876 topography Methods 0.000 description 1
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Abstract
The invention relates to the technical field of composite material processing, in particular to a method for determining milling parameters of a profile of a composite material component based on surface roughness Sz, which comprises the steps of establishing a theoretical model of the surface roughness Sz of the carbon fiber composite material component subjected to profile milling; establishing an objective function based on a machining quality requirement and a machining efficiency maximization principle; and solving the simultaneous surface roughness Sz theoretical model and the objective function to obtain milling parameters including feeding and cutting width. The method can effectively solve the problems of complex, tedious and high cost of the traditional determination method of the profile milling parameters of the carbon fiber composite material component.
Description
Technical Field
The invention relates to the technical field of composite material processing, in particular to a surface roughness Sz-based composite material component profile milling parameter determination method.
Background
Among the numerous composites, carbon fiber composites are the most widely used type of fiber reinforced resin matrix composites. Compared with other materials, the carbon fiber composite material has excellent comprehensive performance and has great advantages in indexes such as specific stiffness, specific strength, thermal conductivity, corrosion resistance and the like. Currently, carbon fiber composite materials have gradually become a new generation of mainstream aviation structural materials. In the field of civil airliners, the composite material consumption of the air passenger A380 is about 25%, the precedent of using a large amount of composite materials for large-scale civil airliners is opened, and after that, the composite material consumption of the civil airliners is continuously refreshed by the Boeing B787 and the air passenger A350 XWB. In aircraft, carbon fiber composite is mainly used for important structural parts such as aircraft skins, panels, hatches, wings, center boxes and the like.
The carbon fiber composite material component with the complex structure is generally prepared in a near net shape forming mode, namely, a fiber preform is woven according to the current situation of the component, a special mold is designed for matrix curing, and the obtained blank structure and size are basically similar to those of a final component. However, the subsequent carbon fiber components also involve assembly and use, and therefore profile milling must be performed to obtain high quality and high precision aerodynamic and assembly surfaces. In order to meet the service performance requirements of the carbon fiber component, the surface machining quality is required to have roughness.
When milling parameters are selected in the process of making a processing technological scheme, the conventional method at present is to firstly develop a parameter test, set an orthogonal test comprising parameters such as rotating speed, feeding speed, cutting width, cutting depth and the like, then develop the milling test, measure the surface roughness obtained by corresponding processing of each group of parameters, then analyze, and select a group of parameters meeting the roughness requirement for processing parts according to the scheme. However, the conventional method consumes a lot of time, a lot of tests are required to be carried out, the input test cost is very high, and the application and popularization of the carbon fiber composite material in the complex-structure aviation structural member are difficult to support.
Disclosure of Invention
In order to solve the technical problems, the invention provides a surface roughness Sz-based composite material component profile milling parameter determination method, which can effectively solve the problems of complexity, complexity and high cost of the traditional carbon fiber composite material component profile milling parameter determination method.
The invention is realized by adopting the following technical scheme:
The surface roughness Sz-based composite member profile milling parameter determination method comprises the following steps:
Establishing a theoretical model of the surface roughness Sz of the carbon fiber composite material member after profile milling:
when the cutting width Ae is less than or equal to 2 (R-Ap), and In the time-course of which the first and second contact surfaces,
；
Wherein Ae is the cutting width, R is the bottom angle of the profile machining tool, ap is the cutting depth, S is the rotation speed, f is the feed, D is the diameter of the profile machining tool, and N is the number of teeth of the tool;
based on the principle of maximizing the processing quality requirement and the processing efficiency, establishing an objective function: ；
And solving a simultaneous surface roughness Sz theoretical model and an objective function to obtain milling parameters including a feed f and a cutting width Ae.
The simultaneous surface roughness Sz theoretical model and the objective function are solved to obtain milling parameters, and the method specifically comprises the following steps:
S 1, determining a cutting depth Ap and a surface roughness Sz;
S 2, combining the theoretical model of the surface roughness Sz and the objective function to obtain an increasing function related to the feed f, and further determining the feed f;
S 3, calculating the cutting width Ae according to the determined feeding f.
The method for determining the cutting depth Ap comprises the following steps:
depth of cut Ap = blank thickness-part theoretical thickness, and the depth of cut Ap meets the following requirements:
。
The rotation speed S=the highest rotation speed of the machine tool-2000 r/min.
The rotation speed S=the external excitation frequency k of flutter-free machining/the number of teeth N of the cutter; the external excitation frequency k of the flutter-free machining is determined after the machining mode of the part is calculated through simulation.
Said further determination of the feed f refers in particular to: feed f=maximum feed speed of machine spindle.
The safety margin is 0.6-0.8.
When the cut width Ae > 2 (R-Ap), the surface roughness sz=the cut depth Ap; when the cutting width Ae is less than or equal to 2 (R-Ap), andWhen, surface roughness sz=cut depth Ap.
Compared with the prior art, the invention has the beneficial effects that:
1. Compared with the surface roughness Sa and the surface roughness Sq, the surface roughness Sz numerical value is the largest when the theoretical morphology is calculated, so that the harshest surface roughness Sz index is selected as the evaluation standard. According to the machining quality requirement and the machining efficiency maximization, an objective function is established, cutting parameters are determined from a theoretical level according to the requirements of different machining quality on surface roughness Sz, a large number of repeated cutting parameter matching tests can be avoided in the early stage, test cost and labor cost for obtaining parameters by means of tests are greatly saved, and the method can be used for obtaining the profile milling parameters of the carbon fiber composite material component efficiently and at low cost. Wherein the surface roughness Sa means the number average height, the surface roughness Sq means the root mean square height, and the surface roughness Sz means the maximum in-plane height.
2. The cutting parameters obtained by the method are applied to production practice, so that the cutting efficiency can be greatly improved, and the product processing period can be shortened.
3. In the invention, the determination of the cutting depth Ap can avoid the surface morphology from being in a groove shape along the cutting width direction after the profile milling or from being in a discontinuous pit shape along the feeding direction after the profile milling.
4. For the surface processing of the carbon fiber component, under the condition that other parameters are consistent, the higher the rotating speed is, the better the processed surface quality of the surface is. The present invention thus provides two methods of determining the rotational speed S, both of which achieve the above-described effects.
5. In the invention, when the feeding f is determined, the cutting speed limit of the main shaft of the machine tool and a certain safety margin are considered, so that the accuracy of the machine tool is prevented from being influenced by excessive cutting force, and the surface of the molded surface is prevented from generating pits, grooves and other unexpected defects.
Drawings
The invention will be described in further detail with reference to the drawings and detailed description, wherein:
FIG. 1 is a cutting theory morphology of example 4 of the present invention;
FIG. 2 is a schematic diagram showing the theoretical residual height of the machined surface when Ae > 2 (R-Ap);
FIG. 3 shows that Ae.ltoreq.2 (R-Ap), A theoretical residual height schematic diagram of the processed surface;
Fig. 4 is a schematic view of adjacent cutter teeth cutting in the same period.
Detailed Description
Example 1
As a basic embodiment of the invention, the invention comprises a composite member profile milling parameter determination method based on surface roughness Sz, which comprises the following steps:
Establishing a theoretical model of the surface roughness Sz of the carbon fiber composite material member after profile milling:
when the cutting width Ae is less than or equal to 2 (R-Ap), and In the time-course of which the first and second contact surfaces,
；
Wherein Ae is the cutting width, R is the bottom angle of the profile machining tool, ap is the cutting depth, S is the rotational speed, f is the feed, D is the diameter of the profile machining tool, and N is the number of teeth of the tool.
Based on the principle of maximizing the processing quality requirement and the processing efficiency, establishing an objective function:
。
and solving to obtain milling parameters. The method specifically comprises the following steps: determining a cutting depth Ap according to the number of teeth N of the cutter, the rotating speed S and the bottom angle R of the profile machining cutter; and then, combining the theoretical model of the surface roughness Sz and an objective function, determining the feed f according to the requirements of the surface roughness Sz of different machining qualities, and finally, determining the cutting width Ae.
Example 2
As a preferred embodiment of the invention, the invention comprises a surface roughness Sz-based composite member profile milling parameter determination method, which comprises the following steps:
Establishing a theoretical model of the surface roughness Sz of the carbon fiber composite material member after profile milling:
when the cutting width Ae is less than or equal to 2 (R-Ap), and In the time-course of which the first and second contact surfaces,
。
In the above formula, ae is the cutting width, R is the bottom angle of the profile machining tool, ap is the cutting depth, S is the rotational speed, f is the feed, D is the diameter of the profile machining tool, and N is the number of teeth of the tool.
Based on the principle of maximizing the processing quality requirement and the processing efficiency, establishing an objective function:
。
and solving a simultaneous surface roughness Sz theoretical model and an objective function to obtain milling parameters including a feed f and a cutting width Ae. The method specifically comprises the following steps:
And S 1, determining the cutting depth Ap and the surface roughness Sz.
S 2, combining the theoretical model of the surface roughness Sz and the objective function to obtain an increasing function about the feed f, and further determining the feed f.
S 3, calculating the cutting width Ae according to the determined feeding f.
Wherein, the feed f=maximum feed speed of the machine spindle is a safety margin, and the safety margin is 0.6.
Example 3
As another preferred embodiment of the present invention, the present invention includes a method for determining profile milling parameters of a composite member based on surface roughness Sz, comprising the steps of:
Establishing a theoretical model of the surface roughness Sz of the carbon fiber composite material member after profile milling:
when the cut width Ae > 2 (R-Ap), the surface roughness sz=the cut depth Ap;
When the cut width Ae is less than or equal to 2 (R-Ap), along the feeding direction, there are the following two cases:
P1: when (when) When, surface roughness sz=cut depth Ap;
P2: when (when) In the time-course of which the first and second contact surfaces,
。
In the above formula, ae is the cutting width, R is the bottom angle of the profile machining tool, ap is the cutting depth, S is the rotational speed, f is the feed, D is the diameter of the profile machining tool, and N is the number of teeth of the tool.
Based on the principle of maximizing the processing quality requirement and the processing efficiency, establishing an objective function:
。
and solving a simultaneous surface roughness Sz theoretical model and an objective function to obtain milling parameters including a feed f and a cutting width Ae. The method specifically comprises the following steps:
And S 1, determining the cutting depth Ap and the surface roughness Sz.
Wherein, the depth of cut Ap = blank thickness-part theoretical thickness.
When the cutting width Ae is more than 2 (R-Ap), sz=ap, and the surface morphology after profile milling presents a groove shape along the cutting width direction, which should be avoided in the actual machining process. And when Ae is less than or equal to 2 (R-Ap),When sz=ap, the surface topography after profile milling is in the form of intermittent pits along the feed direction, which should be avoided during actual machining.
The depth Ap also needs to meet the following requirements:
so that the theoretical model of the surface roughness Sz in the case of P2 can be satisfied.
In general, the cutting depth of the profile processing of the carbon fiber member is not more than 1mm at present, and even not more than 0.5mm generally, so that the P2 condition is generally satisfied, and if the P1 condition is satisfied, the cutting depth Ap needs to be selected again.
Wherein, for the processing of the molded surface of the carbon fiber component, under the condition that other parameters are consistent, the higher the rotating speed is, the better the processed surface quality of the molded surface is. Thus, there are two schemes for determining the rotational speed here:
1) A rotation speed determination scheme is directly given according to the maximum rotation speed of the main shaft of the machine tool, namely the rotation speed S=the maximum rotation speed of the machine tool-2000 r/min.
2) The method is formulated according to the principle of avoiding the vibration mode of the part machining, the vibration mode of the part machining can be calculated through simulation, the vibration-free machining external excitation frequency k is determined, and then the rotating speed S=the vibration-free machining external excitation frequency k/the cutter tooth number N.
S 2, combining the theoretical model of the surface roughness Sz and the objective function to obtain an increasing function about the feed f, which shows that the cutting efficiency is higher as the theoretical feed is larger, but the feed f cannot be increased without limitation. In this case, the limitation in terms of cutting force can be explained: the feeding speed is selected to be related to the cutting force of the cutter, under the same condition, the larger the feeding speed is, the larger the material removal rate is, and the larger the cutting force is, but the excessive cutting force can influence the precision of the machine tool due to the rigidity of the spindle, so that the surface of the molded surface is provided with pits, grooves and other unexpected defects. The present embodiment therefore takes into account the machine spindle cutting speed limit and applies a certain safety margin to the feed speed such that the feed f=the machine spindle maximum feed speed. The safety margin is determined by the rigidity of the spindle and the cutting force, namely the cutting force cannot cause uncompensated machining precision loss caused by spindle deformation and vibration, so that the safety margin can be 0.6-0.8.
S 3, calculating the cutting width Ae according to the determined feed f, and obtaining all milling parameters.
Example 4
As another specific embodiment of the invention, the method for determining the profile milling parameters of the composite member based on the surface roughness Sz is included. Specifically, in the condition that the surface quality, namely the surface roughness Sz, of a certain item of carbon fiber component is required to be within 6.3 mu m, a phi 20R5 four-tooth milling cutter is adopted for profile machining, the theoretical cutting depth Ap is 0.4mm, the maximum cutting feed speed of a machine tool is 12000mm/min, and the maximum rotating speed of the machine tool is 20000R/min, so that the machining rotating speed is defined to be 18000R/min. There are two situations:
1) When the cutting width Ae is more than 2 (R-Ap) =9.2 mm, sz=0.4 mm is more than 6.3 μm, the theoretical residual height of the machined surface can be shown in fig. 2 of the specification, the machined surface of the molded surface of the component is in a gully shape, and the roughness Sz is 0.4mm, so that the actual machining requirement is not met.
2) When the cutting width Ae is less than or equal to 2 (R-Ap) =9.2 mm, under the current working condition,The P2 condition is satisfied, and the theoretical residual height of the machined surface can be shown in fig. 3 of the specification, and at this time, parameter determination can be performed by using Sz theoretical model:
Substituting the surface roughness Sz, the profile machining tool base angle R, the cutting depth Ap and the rotating speed S into the above formula to obtain the following equation:
（1）
3) The solution of the above equation is not unique, and in order to maximize the cutting efficiency, it is proposed to take the maximum material removal rate as an objective function, that is, the objective function is as follows:
（2）
The above formulas (1) and (2) can be combined together, the objective function is an increasing function about f, and when the feeding speed f=10000 mm/min is selected in consideration of the cutting speed limit of the machine tool spindle and a certain safety margin applied to the feeding speed, the corresponding cutting width ae=0.36 mm at this time is the maximum cutting efficiency.
4) From the above, it can be determined that the cutting parameters with the maximum cutting efficiency at sz=6.3 μm standard are: s=18000 r/min, f=10000 mm/min, ae=0.36 mm, ap=0.4 mm.
And when the milling of the carbon fiber composite material construction molded surface is completed by utilizing the cutting parameters, the cutting schematic diagram of the adjacent cutter teeth around the same can be shown by referring to the figure 4 of the specification, and the theoretical shape of the cutting can be shown by referring to the figure 1 of the specification.
In view of the foregoing, it will be appreciated by those skilled in the art that, after reading the present specification, various other modifications can be made in accordance with the technical scheme and concepts of the present invention without the need for creative mental efforts, and the modifications are within the scope of the present invention.
Claims (7)
1. The surface roughness Sz-based composite member profile milling parameter determination method is characterized by comprising the following steps of: the method comprises the following steps:
Establishing a theoretical model of the surface roughness Sz of the carbon fiber composite material member after profile milling:
when the cutting width Ae is less than or equal to 2 (R-Ap), and In the time-course of which the first and second contact surfaces,
；
Wherein Ae is the cutting width, R is the bottom angle of the profile machining tool, ap is the cutting depth, S is the rotation speed, f is the feed, D is the diameter of the profile machining tool, and N is the number of teeth of the tool;
Based on the principle of maximizing the processing quality requirement and the processing efficiency, establishing an objective function:
；
The simultaneous surface roughness Sz theoretical model and the objective function are solved to obtain milling parameters, wherein the milling parameters comprise feed f and cutting width Ae, and the method specifically comprises the following steps:
S 1, determining a cutting depth Ap and a surface roughness Sz;
S 2, combining the theoretical model of the surface roughness Sz and the objective function to obtain an increasing function related to the feed f, and further determining the feed f;
S 3, calculating the cutting width Ae according to the determined feeding f.
2. The surface roughness Sz-based composite member profile milling parameter determination method of claim 1, wherein: the method for determining the cutting depth Ap comprises the following steps:
depth of cut Ap = blank thickness-part theoretical thickness, and the depth of cut Ap meets the following requirements:
。
3. the surface roughness Sz-based composite member profile milling parameter determination method of claim 2, wherein: the rotation speed S=the highest rotation speed of the machine tool-2000 r/min.
4. The surface roughness Sz-based composite member profile milling parameter determination method of claim 2, wherein: the rotation speed S=the external excitation frequency k of flutter-free machining/the number of teeth N of the cutter; the external excitation frequency k of the flutter-free machining is determined after the machining mode of the part is calculated through simulation.
5. The surface roughness Sz based composite member profile milling parameter determination method of claim 3 or 4, wherein: said further determination of the feed f refers in particular to: feed f=maximum feed speed of machine spindle.
6. The surface roughness Sz based composite member profile milling parameter determination method of claim 5, wherein: the safety margin is 0.6-0.8.
7. The surface roughness Sz-based composite member profile milling parameter determination method of claim 1, wherein: when the cut width Ae > 2 (R-Ap), the surface roughness sz=the cut depth Ap; when the cutting width Ae is less than or equal to 2 (R-Ap), andWhen, surface roughness sz=cut depth Ap.
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| CN112620749A (en) * | 2020-12-15 | 2021-04-09 | 成都飞机工业（集团）有限责任公司 | Milling method for arc-shaped surface of carbon fiber joint |
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| WO2023226322A1 (en) * | 2022-05-25 | 2023-11-30 | 沈阳工业大学 | Mechanism- and data driving-based engine cylinder head milled surface quality prediction method |
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Patent Citations (4)
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|---|---|---|---|---|
| CN108549320A (en) * | 2018-03-28 | 2018-09-18 | 西北工业大学 | A kind of titanium alloy milling parameter and tool wear control method based on roughness |
| CN112620749A (en) * | 2020-12-15 | 2021-04-09 | 成都飞机工业（集团）有限责任公司 | Milling method for arc-shaped surface of carbon fiber joint |
| CN113378307A (en) * | 2021-08-16 | 2021-09-10 | 成都飞机工业（集团）有限责任公司 | Method for judging machinability of compensation layer of airplane component |
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| Title |
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