基于主动调制车削的硬脆材料微结构曲面延性域加工方法研究

针对在硬脆材料上加工微结构曲面存在的表面复杂性和材料难加工性双重难题，本项目提出采用主动调制车削加工方法实现硬脆材料微结构曲面的延性域加工。针对该加工方法，从加工机理、加工质量预测和加工技术等角度，以变作用参数下金刚石刀具与硬脆材料的交互作用机理及对微结构曲面创成质量的影响、主动调制模式对硬脆材料微结构曲面延性域加工的影响等关键科学问题为导向，研究变作用参数下硬脆材料的去除机制，揭示各作用参数与材料去除方式和表面加工质量的内在联系，构建与作用参数相关的临界加工尺度和裂纹模型，确定能有效提高临界加工尺度的主动调制模式，建立变作用参数下硬脆材料微结构曲面的加工模型并据此开发加工仿真系统模拟加工过程、预测加工质量和优化加工参数，并以有效主动调制模式为导引，开发新型主动调制车削加工系统验证所提原理、方法和技术。研究成果可为基于主动调制车削的硬脆材料微结构曲面延性域加工提供一种理论依据和实施技术。

Machining of micro-structured surfaces on hard/brittle materials is difficult due to the complexity of the surface and the machinability of the material. In this project, a new processing technique named active-modulated turning (AMT) is proposed to realize ductile machining of micro-structured surfaces on hard/brittle materials. The proposed processing technique will be studied from the perspectives of the machining mechanism, prediction of machining quality, machining technique etc. The main scientific problems of this research are the interactive mechanism between the diamond tool and hard/brittle materials and its influence on the formation of the micro-structured surface, and the influence of the modulation method on the ductile machining of micro-structured surfaces on hard/brittle materials. Guided by these problems, the removal mechanism of the hard/brittle material considering the varied influential parameters will be studied to reveal the relationship between the tool-material interactive mechanism and the machined surface, to establish models for the critical depth-of-cut (DOC) and fracture, and to determine the modulation method which is able to effectively increase the critical DOC. Furthermore, a model for the machining of micro-structured surfaces on hard/brittle materials with varied influential parameters will be built for developing a machining simulation system to simulate the machining process, predict the machining quality and optimize the machining parameters. Based on the effective modulation method, a new AMT machining system will be developed to verify the proposed principles, methods and techniques. In summary, the research in this proposal will provide us the theoretical basis and an implementation technique for the ductile machining of micro-structured surfaces on hard/brittle material using AMT.