基于细观仿真建模的CFRP纵扭超声铣削材料去除机理研究

doi:10.3969/j.issn.1004-132X.2025.04.013

摘要/Abstract

摘要： 为揭示碳纤维增强树脂基复合材料（CFRP）纵扭超声振动铣削材料去除机理，展开了CFRP细观切削仿真研究。分析了纵扭超声振动铣削运动学特性，建立了CFRP材料三维细观切削模型。仿真对比了传统切削与纵扭超声振动切削在不同纤维方向角下的纤维去除机制、基体损伤、切屑形态及切削力。结果表明，0°纤维方向角时，纵扭超声振动冲击特性加速了纤维弯断进程，刃口去除纤维机制由传统碾压转变为划擦；45°和90°纤维方向角时，冲击作用增强了切削刃对纤维的剪切效果，90°纤维方向角时剪切效果更显著；135°纤维方向角时，纤维去除机制由大面积弯断转变为局部断裂。纵扭超声振动铣削有利于抑制基体损伤，改善切屑形态，减少切削区域热量积累，减小平均切削力。最后通过实验验证了仿真分析的准确性。

关键词: 碳纤维增强树脂基复合材料, 纵扭超声振动, 细观仿真, 材料去除机理, 纤维方向角

Abstract: In order to reveal the material removal mechanism of CFRPs in longitudinal-torsional ultrasonic vibration milling, a simulation study of CFRP mesoscopic-cutting was carried out. The kinematic characteristics of longitudinal-torsional ultrasonic vibration milling were analyzed, and a 3D mesoscopic-cutting model of CFRPs was established. The fiber removal mechanism, matrix damage, chip morphology and cutting force of conventional cutting and longitudinal-torsional ultrasonic vibration cutting were compared under different fiber orientation angles. The results show that when the fiber orientation angle is 0°, the longitudinal-torsional ultrasonic vibration cutting impact characteristics accelerate the fiber bending processes, and the fiber removal mechanism at the cutting-edge changes from conventional rolling to scratching. When the fiber orientation angle is 45° and 90°, the impact characteristics enhance the shear effects of the cutting-edge on the fiber, especially when the fiber orientation angle is 90°. When the fiber orientation angle is 135°, the fiber removal mechanism changes from large area bending to local fracture. Longitudinal-torsional ultrasonic vibration milling is beneficial to restrain matrix damage, improve chip morphology and reduce heat accumulation in the cutting areas and decrease the average cutting forces. The experiments verify the accuracy of the simulation analysis.

Key words: carbon fiber reinforced polymer（CFRP）, longitudinal-torsional ultrasonic vibration, mesoscopic simulation, material removal mechanism, fiber orientation angle

中图分类号:

TH162
V258

张超1, 任莹晖1, 2, 于晓琳1, 李茂君2, 余承阳2, 杜新亮1. 基于细观仿真建模的CFRP纵扭超声铣削材料去除机理研究[J]. 中国机械工程, 2025, 36(04): 760-769,779.

ZHANG Chao1, REN Yinghui1, 2, YU Xiaolin1, LI Maojun2, YU Chengyang2, DU Xinliang1. Material Removal Mechanism of CFRP in Longitudinal-torsional Ultrasonic Milling Based on Mesoscopic Simulation Model[J]. China Mechanical Engineering, 2025, 36(04): 760-769,779.

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https://www.cmemo.org.cn/CN/Y2025/V36/I04/760

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