铝蜂窝芯材料切削力热建模与低缺陷加工关键技术

Composite honeycomb sandwich structure is widely used in aerospace field due to its excellent material properties. Form quality and load capacity of composite honeycomb sandwich structure are depend on machining accuracy and quality of honeycomb core. This project focused on the technical bottlenecks of unclear machining mechanics, lack of reliable and stable clamping system and special cutting tools, being short of adaptive machining process, established the cutting force model and cutting temperature distribution model based on the mechanics behavior and heat transmission behavior. The key factors of machining defects appearance were studied according to the cutting force and heat transfer mechanism. New aluminum honeycomb core clamping equipment was developed based on the semiconductor refrigeration technique. The cutting tool design method based on the no-defect critical cutting force was proposed and the special cutting tools for aluminum honeycomb core were manufactured by tool edge enhanced technique and nano-diamond coating. Machining process was optimized by analyzing the relation between machining defects and cutting tool path and cutting parameters. The set of technique of machining mechanics, clamping system, special cutting tools and adaptive machining process was applied to machining aluminum honeycomb core in the large aircraft.

复合材料蜂窝夹层结构因其优异的材料性能在航空航天领域获得广泛应用，其成型质量和承载能力取决于蜂窝芯的低缺陷加工。本项目通过建立各向异性非连续结构铝蜂窝芯切削力和切削热定向传递模型，以及蜂窝壁和蜂窝芯格发生塑性坍塌的临界切削力模型，揭示铝蜂窝芯加工缺陷形成机理。开发基于半导体快速制冷技术的新型冰结铝蜂窝芯夹持装置；提出基于铝蜂窝芯无缺陷临界切削力的刀具设计方法，采用定向湿喷砂-弹性抛光-微粉研磨的刃口复合强化技术和纳米金刚石涂层技术制备铝蜂窝芯专用刀具；研究不同切削条件下铝蜂窝芯加工缺陷分布规律，建立加工质量评价体系，提出铝蜂窝芯规律性缺陷（蜂窝壁和蜂窝芯格塑形变形、坍塌和毛刺）规避的加工路径优化策略和非规律性缺陷（双层边脱胶、节点失效、纵向撕裂、底面撕裂）规避的工艺参数优化方法；形成铝蜂窝芯低缺陷加工机理-夹持装备-专用刀具-适配工艺成套技术，应用于大型客机复合材料夹层结构中铝蜂窝芯加工。

复合材料技术是航空航天装备轻量化和高效能化的关键技术，其用量成为航空航天飞行器先进性的标志。以碳纤维复合材料为上下面板组成的蜂窝芯夹层材料，具有高比强度、高比模量、低膨胀系数、极佳的抗压抗弯性能、隔热隔音性能以及超轻型结构特征的优良特点，已经广泛应用于航空航天领域。蜂窝芯加工精度和质量直接决定了复合材料蜂窝夹层结构成型质量及承载能力。蜂窝芯材料的高效高质加工已成为我国航空航天制造企业亟待解决的共性难题。针对铝蜂窝芯材料切削加工缺陷多发，加工质量难以控制，专用高性能加工刀具缺乏，加工工艺优化缺少机理研究作为指导等问题，项目建立了铝蜂窝芯切削力定向传递和切削热定向传导模型，揭示了铝蜂窝芯加工缺陷形成机理；开发了铝蜂窝芯快速制冷冰结夹持装备，设计和制备专用铝蜂窝芯高性能切削刀具；以规避铝蜂窝芯切削中产生规律性缺陷（蜂窝壁和蜂窝芯格塑形变形、坍塌及毛刺）为目标，提出典型工艺下铝蜂窝芯低缺陷加工路径优化策略；以规避铝蜂窝芯切削中产生非规律性缺陷（双层边脱胶、节点失效、纵向撕裂、底面撕裂毛刺）为目标，优化铝蜂窝芯切削加工工艺参数，最终形成了铝蜂窝芯低缺陷加工机理-夹持装备-专用刀具-适配工艺成套技术，在大型客机复合材料蜂窝夹层结构中实现铝蜂窝芯低缺陷加工。项目研究需求来源于国家航空航天飞行器蜂窝芯加工过程中的生产实际问题，针对国家大型客机、军用直升机、卫星和雷达等重大工程对蜂窝芯加工技术的需求，研究铝蜂窝芯低缺陷切削加工成套技术，并推动相关成果应用于生产实践，有利于推动先进复合材料蜂窝夹层结构使用性能和服役性能的提升，不仅有助于降低企业生产制造成本，而且有利于保障生产制造的技术安全，具有重要的研究意义和研究价值。

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