Research on cutting burrs in high speed milling of aluminum alloy plane with diamond coated tools
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摘要: 采用热丝 CVD 法制备纳米与微米金刚石薄膜涂层刀具,利用场发射扫描电镜表征其薄膜表面形貌。用已制备的 CVD 金刚石涂层刀具,在无润滑干切条件下高速顺、逆端铣铝合金平面,研究CVD金刚石涂层刀具切削时的棱边毛刺特点与大小;并对纳米金刚石涂层刀具高速顺铣切削工艺参数进行正交试验,探究取得少无切削毛刺的切削参数与切削工艺。结果表明:工件铣削后棱边毛刺分布不均匀,顺铣毛刺稀疏,尺寸较小,其中纳米金刚石涂层刀具顺铣棱边毛刺高度平均值为32.08 μm,仅为微米金刚石涂层刀具顺铣毛刺高度的46.5%。纳米金刚石涂层刀具高速顺铣平面,对棱边毛刺影响最大的是vc,其次为vf,ae的影响最小,最优参数组合为ae=4 mm、vf=2 000 mm/min、vc=400 m/min,铣削后毛刺高度平均值为21.29 μm。当金刚石涂层刀具端铣铝合金平面时,为取得较小的棱边毛刺,优选纳米金刚石涂层刀具,采用顺铣棱边的切削方式与切削工艺,以及相应的高速切削参数。Abstract: The nano and micro diamond film coated tools were prepared by the hot wire CVD method.The surface morphology of the film was characterized by field emission scanning electron microscopy. The prepared CVD diamond coated tools were used to end mill the aluminum alloy surface forward and backward at high speed under the condition of dry cutting without lubrication. It studies the characteristics and size of edge burrs during high-speed end milling of aluminum alloy using CVD diamond coated tools. It carries out orthogonal tests on cutting process parameters to explore the cutting parameters and processes with little or no cutting burr when nano-diamonds coated tools are used for high-speed forward milling. The results show that the distribution of burrs on the edges of the workpiece is uneven after milling, and the burrs during forward milling are sparse and small in size. Among them, the average height of burrs on the edges during forward milling with nano diamond coated tools is 32.08 μm, only 46.5% of the forward milling burr height of micrometer diamond coated tools. When nano diamond coated tools are used for high-speed forward milling of flat surfaces, vc has the greatest impact on edge burrs, followed by vf, and ae has the weakest impact. The optimal parameter combination for high-speed milling is ae=4 mm, vf=2 000 mm/min, and vc=400 m/min. The average burr height after milling is 21.29 μm. When the diamond coated tool is used to end mill the aluminum alloy plane, in order to obtain a small burr, the nano diamonds coated tool is selected, the cutting method of forward milling and the corresponding high-speed cutting parameters are adopted.
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Key words:
- diamond coated tools /
- end milling /
- edge burrs /
- cutting parameters /
- process path
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表 1 切削毛刺正交实验因素水平表
Table 1. orthogonal experimental factors for cutting burrs
水平 因素 径向切削深度
ae/ mm
A进给速度
vf / (mm·min−1)
B切削速度
vc / (m·min−1)
C1 3 1 000 300 2 4 2 000 400 3 5 3 000 500 表 2 切削毛刺正交实验组合及结果
Table 2. Orthogonal test combination and results for cutting burrs
试验
编号参数组合 毛刺高度h / μm 毛刺平均高
度$\overline h $ / μm1 A1B1C1 104.82,84.83,48.88,80.75,97.82 83.42 2 A1B2C2 24.48,19.63,18.72,23.24,24.23 22.06 3 A1B3C3 31.71,95.31,112.04,99.39,90.55 85.80 4 A2B1C2 34.57,54.07,24.44,44.12,46.43 34.57 5 A2B2C3 29.33,24.59,26.84,34.71,28.88 28.87 6 A2B3C1 46.67,70.63,60.61,50.08,65.26 58.65 7 A3B1C3 36.72,53.08,151.54,46.54,72.32 72.04 8 A3B2C1 49.23,88.61,53.71,73.37,65.13 66.01 9 A3B3C2 48.48,65.55,60.37,51.41,61.08 57.38 表 3 各切削参数影响的毛刺高度均值以及极差R值
Table 3. The average and range R values of burr height affected by various cutting parameters
项目 取值 径向切削深度
ae / mm
A供给速度
vf / (mm·min−1)
B铣削速度
vc / (m·min−1)
C均值t1 63.76 63.34 69.36 均值t2 40.70 38.98 38.00 均值t3 65.14 67.28 62.24 极差R 24.44 28.30 31.36 -
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