目的 为了提升铝合金磨削表面的加工质量,选取2214铝合金为研究对象,旨在深入探究单颗磨粒划擦工艺参数对材料去除行为的影响机制。方法 本文开展了2214铝合金单颗磨粒划擦试验,并采用响应面法（RSM）优化划擦线速度、工件进给速度和划擦深度工艺参数。以材料去除分数av和划擦力系数q为响应量,建立了二阶回归模型,用于分析不同划擦参数对材料去除行为的影响。结果 试验结果表明,划擦线速度对av和q影响显著,其次是划擦深度,而进给速度对av和q表现为不显著。最优工艺参数试验组合经试验验证,av较优化前增加了2.3%,q减小了1.7%,对比预测分别相差2.0%和6.4%。结论 针对2214铝合金的单颗磨粒划擦过程,划擦线速度是控制材料去除效率和划擦力的关键因素,优化后的划擦工艺参数能有效减少表面损伤。
Abstract
High-strength aluminum alloys represent a class of critical materials extensively utilized in the aerospace industry, primarily due to their exceptional specific strength, commendable corrosion resistance, and favorable machinability. Among them, the 2214 aluminum alloy is a prominent choice for structural components. Nevertheless, a comprehensive understanding of the surface generation mechanisms during grinding processes—a pivotal finishing operation—remains elusive. This knowledge gap is particularly evident concerning the intricate and competing interplay between strain rate sensitivity, which may lead to material hardening, and thermal softening behavior, which facilitates plastic flow. To bridge this gap, the present study employs a fundamental single-grit scratching approach to investigate the 2214 high-strength aluminum alloy, aiming to elucidate the underlying material removal mechanisms and its explicit dependence on key scratching parameters.
For the experimental methodology, it was designed to isolate and simulate the fundamental interaction between a single abrasive grain and the workpiece. Scratching tests were conducted using a precisely engineered diamond indenter with a well-defined geometry. This setup was integrated within a Computer Numerical Control (CNC) grinding machine, ensuring high-precision control over kinematic parameters. A comprehensive suite of diagnostic tools, including a white light interferometer for topographical analysis, an optical microscope for morphological observation, and a high-resolution force sensor for dynamic measurement, was employed to characterize both the kinematic and dynamic aspects of the process. To systematically model and optimize the process, Response Surface Methodology (RSM) was implemented. This statistical technique enabled the development of robust mathematical models that correlated critical input parameters (e.g., scratching speed, depth, feed rate) with two pivotal output responses: Material Removal Fraction (av) and the Scratch Force Coefficient (q). It is noteworthy that av was quantitatively characterized by measuring the cross-sectional area of the scratch groove at its deepest point, representing the volumetric material removal efficiency. Concurrently, the scratch force coefficient, a parameter indicative of the specific energy and friction during deformation, was derived from the measured normal force normalized by the projected contact area.
The experimental results yield significant insights. A central finding is that the scratching linear speed exerts the most profound influence on both av and the scratch force coefficient. This dominance is attributed to a fundamental transition in the material response mechanism: at lower speeds, the predominant mode is plastic ploughing and side-flow, whereas at elevated speeds, the high strain rates promote a shift towards more efficient brittle chip formation and ejection. Furthermore, a critical observation is the consistent reduction in the scratch force coefficient with increasing scratching speed. This phenomenon strongly suggests that within the high-strain-rate deformation zone, the thermal softening effect—whereby frictional heat reduces the material's flow stress—becomes the dominant factor, overwhelming the competing effect of strain rate hardening. Through the application of RSM optimization algorithms, an optimal set of scratching parameters is identified that simultaneously maximizes av and minimizes the scratch force coefficient. Subsequent validation experiments confirm the model's efficacy, demonstrating a 2.3% enhancement in av and a 1.7% reduction in the scratch force coefficient compared with baseline pre-optimized conditions.
In conclusion, this research provides seminal mechanistic insights into the material removal behavior of the 2214 aluminum alloy during grit interaction. It unequivocally reveals that the resultant surface formation during grinding is governed by a complex synergy between strain rate effects and the thermal-mechanical response of the material. The developed second-order regression model establishes a quantitative and predictive framework for anticipating material behavior under a wide spectrum of grinding conditions. The findings offer substantial theoretical significance for understanding high-strain-rate deformation in alloys and possess considerable practical value for optimizing industrial grinding processes, ultimately leading to improved surface integrity, extended tool life, and enhanced manufacturing efficiency for high-strength aluminum components in aerospace and other high-tech sectors.
关键词
2214铝合金 /
单颗磨粒划擦 /
加工质量 /
响应面法 /
参数优化
Key words
2214 aluminum alloy /
single-grit scratching /
processing quality /
response surface methodology /
parameter optimization
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基金
国家自然科学基金联合基金项目（U25B20154）
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