颗粒增强铝基复合材料高功率激光-铣削协同加工关键技术研究

颗粒增强铝基复合材料近年来在航空航天等领域广泛应用，但现有加工技术已成为制约其推广应用的关键环节。为解决目前铝基复合材料薄壁件铣削加工中刀具磨损严重、加工效率低和激光加工中热损伤等问题，本项目提出铝基复合材料高功率激光-铣削协同加工的方法，创新性地结合高功率激光高效率去除和铣削低损伤加工的优势，并基于残余应力分布特征量与关键工艺要素间的数学映射关系优化加工表面层残余压应力分布，实现铝基复合材料薄壁件的高效低损伤加工。研究高功率激光切割铝基复合材料温度场和热应力分布规律，并准确预测变质层宽度，实现最小切削量的连续铣削加工；阐明多热力场叠加作用下耦合应力场的分布演变机理和加工表面层残余压应力调控机理，形成铝基复合材料高效低损伤加工理论和技术。研究成果对促进铝基复合材料的进一步应用具有重要意义。

Particle reinforced aluminium matrix composites have been widely used in aerospace and other fields in recent years, but the existing processing technology has become a key step that restricts its application. In order to solve the problems including severe tool wear, low efficiency following traditional milling and thermal damage in laser cutting of thin-walled aluminium matrix composites, high-power laser-milling cooperative machining process is proposed to cut aluminium matrix composites in this project, which combines the advantages of high material removal rate with laser cutting and low level of damage with milling process. Based on the mathematical mapping between residual stress distribution and the key process parameters, it can optimize the distribution of residual compressive stress in the machined surface layer, and achieve high-efficiency and low-damage processing of thin-walled aluminum matrix composites. The temperature field and thermal stress distribution of high-power laser cutting aluminium matrix composites are studied, and the width of heat affected layer is accurately predicted to achieve continuous milling with minimum cutting depth. The evolution mechanism of coupled stress field under the effect of initial thermal stress fields and the regulation mechanism of residual compressive stress in subsurface layer are explained, and the theory and technology of high-efficiency and low-damage processing of aluminium matrix composites are formed. The research results are of great significance to promote the further application of aluminum matrix composites.