基于界面力学性能分析的芳纶纤维高效高质量切削加工工艺研究

A large amount of practical experience in aerospace industry indicates that many accidents caused by structural failure of composite materials originate from processing defects of composite materials. Due to the high toughness and low thermal conductivity of aramid fiber composites (AFRP), many processing defects such as drawing, burr, delamination and tearing are more prone to occur during cutting process. This project investigates the defects forming mechanism and surface quality controlling during milling process, reveals the forming mechanism of defects and puts forward the control strategies of machined surface defects. . Based on the theory of cutting force and controlling strategies of machined surface defects, the effect of fiber angle variation on deformation of cutting force and interfacial shear strength has been revealed; the cutting speed on controlling the plastic brittleness of AFRP have been investigated to reduce cutting force and suppressing machining defects; the design principle and method for new cutting tool edge and structure has been proposed to improve the machined surface quality; the evaluation mechanism of AFRP machined surface defects has also been developed. . Based on this project, a complete set of milling process can be formed to ensure AFRP milling process with efficiency, low cost, controllable and repeatable manufacturing. Through the cross discipline of manufacturing science, material science, mechanics and other fusion research, original innovations can be made in the aspect of control mechanism of defects formation for other composite materials.

航空航天事业的诸多实际经验表明很多因复合材料结构失效造成的事故往往起源于复合材料的加工缺陷。针对芳纶纤维复合材料韧性大、导热系数低，切削加工过程易出现抽丝、拉毛、分层、撕裂等诸多加工缺陷，本项目从界面力学分析角度出发，研究切削过程中缺陷损伤形成机理，提出已加工表面缺陷控制策略；基于不同纤维角度界面模量计算公式，计算塑性变形时临界载荷值，阐述不同角度下纤维断裂形式及其对切削力的影响规律；实现切削速度在线控制芳纶纤维复合材料塑脆性，在塑脆状态进行切削加工，减小切削力抑制其加工缺陷；基于切削力与界面损伤控制理论，提出铣削刀具刃口、结构设计原理和方法；建立芳纶纤维复合材料铣削表面缺陷评价机制，形成整套铣削加工工艺，保证芳纶纤维复合材料铣削加工的高效、低成本、可控、可重复性制造。通过制造科学、材料学、力学等学科的交叉和深度融合研究，在复合材料加工表面缺陷形成机制及控制方面取得原始创新。

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