目的 探明聚晶金刚石（PCD）铰刀在对铝合金进行铰削过程中,易导致孔壁表面产生周期性分布的黑色条纹的机理,并寻求抑制方法。方法 通过孔壁宏/微观形貌检测、元素分析、物相分析、振动信号采集及有限元仿真等手段分析发黑机理。尝试在铰刀刃带表面设计并制备功能织构开展试验研究,首先通过预试验,初步筛选出300 μm间距的凹坑织构为较优选择,继而将其应用于PCD铰刀开展铝合金干式铰削试验。最终提出并验证“复合织构刀具+微量润滑+游离磨粒光洁”的准干式铰削方案,通过在PCD铰刀前刀面加工出沟槽织构,以实现金刚石磨粒混合润滑介质的输运,同时在刃带表面开设具有储油与容屑功能的凹坑织构,并借助金刚石微粉研磨孔壁表面。结果 分析表明,孔壁表面周期性分布的发黑条纹为含有空位缺陷的非晶态氧化铝覆盖层,其形成是因为铰削振动引发的刃带对孔壁的间歇性挤压摩擦,致使局部温升,进而促使氧化膜周期性集聚并成形。试验显示,PCD铰刀仅采用凹坑织构虽可减轻发黑,但在振动影响下,织构边缘会对孔壁表面产生微切削作用,反而导致孔壁表面粗糙度上升与形状精度下降。采用准干式铰削方案后,消除了发黑现象,孔壁表面粗糙度降低约51.0%,圆度与圆柱度误差分别下降约29.9%与30.5%。结论 “复合织构刀具+微量润滑+游离磨粒光洁”的准干式铰削方案能有效抑制PCD铰刀加工铝合金时的孔壁发黑现象,改善表面质量与形状精度,呈现出更好的加工质量与工艺稳定性。
Abstract
Dry and near-dry reaming are important approaches to achieve green and precision machining of aluminum alloys. However, polycrystalline diamond (PCD) reamers tend to induce periodically distributed black streaks on the hole wall surface during the machining of aluminum alloys, which impairs the surface quality. Therefore, it is necessary to clarify the formation mechanism and explore suppression methods. In this work, a combination of multiple analytical methods was adopted. The macro/micro-topography of the hole wall was observed by laser confocal microscopy and scanning electron microscopy. The elemental composition and phase composition of the blackened areas were characterized by energy dispersive spectroscopy and X-ray diffraction. Meanwhile, the vibration signals during the reaming process were collected online by a laser Doppler vibrometer, and combined with the finite element simulation based on the Johnson-Cook material model, the thermal-mechanical coupled numerical simulation of the temperature field in the cutting zone was carried out. The analysis results show that the periodically distributed black streaks on the hole wall surface are amorphous aluminum oxide coatings with vacancy-type defects. Their formation is attributed to the intermittent extrusion and friction between the reamer margin and the hole wall induced by reaming vibration, which leads to local temperature rise and further promotes the periodic accumulation and formation of oxide films. To suppress the blackening phenomenon, the work aims to design and prepare functional textures on the margin surface of reamers. In the preliminary experiments, the pit texture with a spacing of 300 μm was initially selected as the optimal option, which was then applied to PCD reamers for dry reaming experiments of aluminum alloys. However, experimental results showed that although the blackening could be alleviated to a certain extent, under the impact of cutting vibration, the edges of the textures acted as micro-cutting edges instead, exerting additional micro-cutting effects on the hole wall and resulting in an increase in the surface roughness as well as a decrease in the roundness and cylindricity of the hole wall. To solve the above problem, a synergistic near-dry reaming scheme was proposed, comprising "composite textured tool + minimum quantity lubrication (MQL)+free abrasive finishing". In this scheme, groove textures were fabricated on the rake face of PCD reamers to capture the lubricant mixed with diamond abrasives pre-coated on the hole wall, and relying on the centrifugal force generated by the rotation of the reamer, the mixture was continuously transported to the cutting zone and the margin-hole wall interface, so as to reduce the friction coefficient and cutting force, thereby mitigating the impact of reaming vibration. Meanwhile, pit textures with oil storage and chip accommodation functions were machined on the margin surface, and the hole wall surface was polished with diamond micro-particles. The experimental results indicated that the proposed near-dry reaming scheme achieved remarkable effectiveness. The blackening phenomenon on the hole wall was basically eliminated. Compared with the original dry reaming process, the surface roughness of the hole wall was reduced by approximately 51.0%, and the roundness and cylindricity errors decreased by about 29.9% and 30.5%, respectively, exhibiting better machining quality and process stability.
关键词
铰削 /
表面织构 /
刃带 /
铝合金 /
摩擦
Key words
reaming /
surface texture /
margin /
aluminum alloy /
friction
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基金
国家自然科学基金项目（52405491）; 宁波大学-江北区“双一流”合作专项定向委托科技合作项目（2436）; 宁波市自然科学基金（2024J044）; 宁波市北仑区关键核心技术攻关项目（2025BLG011）; 浙江省省属高校基本科研业务费专项资金资助（SJLY2025001）
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