Surface deformation errors and self-adaptive compensation for microstructured surface generation of titanium alloys
Surface deformation errors and self-adaptive compensation for microstructured surface generation of titanium alloys
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DOI：
10.1016/j.ijmecsci.2022.107736
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发表时间：
2022-09
影响因子：
7.3
通讯作者：
Zhanwen Sun;Shijun Xu-;J. Jiao;Sujuan Wang;S. To;Peizheng Li
中科院分区：
文献类型：
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作者：
Zhanwen Sun;Shijun Xu-;J. Jiao;Sujuan Wang;S. To;Peizheng Li
在微结构表面的金刚石伺服切削（DSC）中，切削运动的振荡不可避免地会引起非均匀表面变形误差。虽然静态和动态的DSC几何误差进行了研究，很少有研究集中在预测和补偿策略的表面变形误差的微结构表面生成。综合考虑动态切削力、材料微观组织演化、热力耦合效应和亚表层应力应变分布，提出了钛合金表面微结构生成模型。为了表征非均匀表面变形误差，并验证所提出的模型，制作了谐波微结构表面。结果表明，该模型能够准确地模拟表面塑性和弹性变形误差随切屑厚度和切削方向的变化。由于切削方向的影响，即使在相同的切削深度下，与下坡切削方向相比，上坡切削方向的已加工表面也会承受更大的塑性应变和塑性变形误差。为了补偿曲面变形误差，提出了一种在传统伺服切削中加入自适应快速刀具伺服的协同伺服切削策略。CSC的瞬时补偿运动由曲率半径偏差、瞬时切削深度和切削方向共同决定。实验结果表明，CSC可以使误差分布更加均匀，对不同微结构表面的峰谷面形误差从1.29 μm减小到0.24 μm。
In diamond servo cutting (DSC) of microstructured surfaces, the oscillated cutting motion inevitably cause non-uniform surface deformation errors. Although static and dynamic geometric errors for DSC have been studied, few studies focus on the prediction and compensation strategies of the surface deformation errors for microstructured surface generation. This study proposes an microstructured surface generation model of titanium alloys by considering the dynamic cutting forces, material microstructure evolution, thermal-mechanical coupling effect and subsurface stress-strain distribution. Harmonic microstructured surfaces are fabricated to characterize the non-uniform surface deformation errors as well as to validate the proposed model. The results show that the proposed model can accurately simulate the variation of surface plastic and elastic deformation errors as a function of undeformed chip thickness and cutting direction. Compared with the downslope cutting direction, the machined surface in upslope direction is subjected to greater plastic strain and plastic deformation errors even at the same depth of cut, due to cutting direction effect. To compensate surface deformation errors, a cooperative servo cutting (CSC) strategy is proposed by incorporating a self-adaptive fast tool servo into conventional servo cutting. The instantaneous compensation motion of CSC is jointly determined by the curvature radius deviation, instantaneous cutting depth and cutting direction. The experimental results show that CSC can make the error distribution more uniform, and greatly decrease the peak-to-valley surface deformation errors from 1.29 to 0.24 μm for different microstructured surfaces.