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Machining of high-performance materials with ultrasonically modulated cutting speed

采用超声波调制切削速度加工高性能材料

基本信息

批准号：
406283248
负责人：
Professor Dr. Gerald Fütterer, since 3/2021
金额：
--
依托单位：
Lehrstuhl für Betriebswissenschaften und Montagetechnik
依托单位国家：
德国
项目类别：
Research Grants
财政年份：
2018
资助国家：
德国
起止时间：
2017-12-31 至 2020-12-31
项目状态：
已结题

来源：
https://gepris.dfg.de/gepris/projekt/406283248?language=en
关键词：
Machining performance materials ultrasonically modulated

项目摘要

In order to meet the constantly increasing requirements with regard to lightweight design and energy efficiency, difficult-to-machine materials such as hard metals, ceramics and fiber-reinforced plastics are gaining in importance. Considering conventional machining processes, these materials can only be machined with high tool wear. Ultrasonic-assisted machining has proved to be suitable to successfully address this issue.In the case of ultrasonically assisted machining, an additional high-frequency oscillation is superimposed on the kinematics of the conventional machining process. This generates oscillations on the tool cutting edge in the region of a few micrometers, thereby causing a high-frequency change in the cutting speed or the feed. Consequently, a reduction in cutting forces, an increase in the tool life as well as an improvement in workpiece quality can be achieved. In milling and grinding it has been shown that these effects are already partially present in the case of a vibration excitation in the axial direction relative to the workpiece, that is perpendicular to the cutting direction. Further improvements of the process results can be achieved by superimposing a vibration in the cutting direction and thus modifying the cutting speed at high frequency.Therefore, the aim of the research project is to provide a basis for vibration-assisted milling and grinding with ultrasonically modulated cutting speed. For this purpose, an ultrasonic actuator is constructed, with which both the milling and the grinding tool can be superimposed with a longitudinal-torsional-ultrasonic vibration. Subsequently, fundamental investigations are carried out for vibration-assisted milling and grinding.During milling, the hard-to-machine titanium Ti-6Al-4V alloy will be machined. The influence of conventional process parameters (speed, feed rate, cutting depth and tool geometry) and oscillation parameters (frequency and amplitude) are evaluated. In doing so, the occurring effects are analyzed aiming at minimizing tool wear and increasing the workpiece quality. At the same time, basic investigations are carried out for the grinding of hard-brittle materials with an ultrasonically modulated cutting speed, in which the interactions between conventional and vibration parameters (amplitude and frequency) are also studied.The milling experiments are carried out on an Ultrasonic linear 40 machine tool, which was provided by the DFG for fundamental studies particularly on vibration-assisted machining.

为了满足不断增长的轻量化设计和能效要求，硬质金属、陶瓷和纤维增强塑料等难加工材料的重要性日益增加。考虑到传统的加工工艺，这些材料只能在刀具磨损很高的情况下进行加工。超声波辅助加工已被证明是适合成功地解决这个问题。在超声波辅助加工的情况下，一个额外的高频振荡叠加在传统的加工过程的运动学。这在刀具切削刃上产生几微米范围内的振荡，从而导致切削速度或进给的高频变化。因此，可以实现切削力的降低、刀具寿命的增加以及工件质量的改善。在铣削和磨削中，已经表明，在相对于工件的轴向方向上（即垂直于切削方向）的振动激励的情况下，这些效应已经部分地存在。通过在切削方向上叠加振动，在高频下改变切削速度，可以进一步改善加工效果，为超声调制切削速度的振动辅助铣削和磨削加工提供依据。为此，构造了超声波致动器，利用该超声波致动器，铣削和磨削工具都可以叠加有扭转超声振动。在此基础上，对振动辅助铣削和磨削进行了基础研究，并对难加工钛合金Ti-6Al-4V进行了铣削加工。传统的工艺参数（速度，进给速度，切削深度和刀具几何形状）和振荡参数（频率和振幅）的影响进行了评估。在这样做的时候，发生的影响进行了分析，旨在尽量减少刀具磨损，提高工件质量。同时，对超声调制切削速度磨削硬脆材料进行了基础研究，研究了常规参数与振动参数（振幅和频率）之间的相互作用，并在DFG公司提供的用于基础研究特别是振动辅助加工的超声直线40机床上进行了铣削实验。