难加工材料高速切削过程中刀具工况特征的跟随感知

难加工材料高速切削过程中，切削区产生的局部高温导致随时空变化的工件变形、刀具磨损与让刀变形，它的获取对控制零件加工质量以及实现刀具磨损预测和切削模型精化等均具有重要意义。本项目针对难加工材料高速切削过程中刀具工况特征在线精确感知需要：1）探索刀具表面微织构设计及沟槽型微织构内薄膜热电偶的高效制作工艺，建立刀具表面微织构与薄膜传感器集成制造方法，实现切削区域内单一测点温度的原位精确测量；2）建立刀具三维瞬态非线性热传导方程，提出基于有限温度测点信息的刀具表面热流快速精确计算方法，实现切削区域温度场的快速重构；3）研究切削加工过程中刀具-工件之间的热力学行为，揭示二者交互作用界面能量演变机制，建立刀具结构几何特征与切削区温度之间的关系模型；4）研制集成薄膜热电偶的表面织构刀具，结合典型应用开展刀具工况特征跟随感知实验。研究成果可为航空薄壁类零件高品质制造提供重要的理论和方法支撑。

During high-speed cutting process of difficult-to-cut materials, high local temperature in the tool-chip interface has its controlling influence on the workpiece deformation, tool wear and recession deformation. Therefore, it is important to obtain the exact temperature rise in the tool-chip interface for quality control of the machined parts, tool wear prediction and cutting model refinement. In order to realize online precise perception of the cutting tools’ operating condition features during high speed cutting process of hard-to-cut materials, the following issues will be studied, including: 1) appropriate design of micro-textures on tool surface and efficient fabrication process of the thin film thermocouples deposited in the micro-grooves are explored, to establish an integrated manufacturing method of surface micro-textures and thin film sensors on cutting tools, which realizes a precise, in-situ temperature measurement of single-points within the cutting area; 2) a three-dimensional transient nonlinear heat conduction equation of the cutting tools based on the dynamic cutting process is established, using the measurement information of finite points in the cutting area, a fast and accurate calculation method for the surface heat flux identification is proposed, to realize a fast temperature field reconstruction of the cutting area; 3) the thermal behaviors between the tool and workpiece are studied, the energy evolution mechanism of the interaction interface is revealed, and a relation model between the tool’s features and the cutting area temperature is built; 4) a micro-texture cutting tool integrated with thin film thermocouples is devised for conducting perceptual experiments regarding the operating condition features of cutting tools. All of the researches herein will provide important theoretical and methodological support for high quality manufacture of the thin-walled parts with difficult-to-cut materials.