目的 镍基高温合金铣削过程中,高切削力与高切削温度易导致刀具快速磨损及表面质量恶化,而单一超声振动加工的润滑冷却能力有限。因此,提出将微量润滑技术与超声振动铣削相结合的方法,并从毛细管润滑渗透机理、热力学仿真分析与铣削实验验证三方面系统研究该工艺改善润滑条件与加工效果的作用机制。方法 基于刀-屑接触区毛细管理论建立正三棱锥模型,揭示润滑渗透机理,通过热-力耦合有限元分析阐明Minimal Quantity Lubrication（MQL）与超声振动协同降低铣削力与温度的作用规律,并通过镍基高温合金铣削实验验证仿真结果的准确性。结果 在MQL辅助超声振动铣削镍基高温合金GH4169的过程中,铣削力较干切削降低20%~35% （当超声振幅由0增至3 μm时,MQL工况下铣削力由约60 N降至50 N）,切削温度最大降幅达14.8%;仿真与实验的铣削力变化趋势高度一致（误差<10%）,切削温度平均误差控制在3.7%~10.3%,验证了所建热-力耦合模型的有效性。结论 MQL对辅助超声铣削GH4169铣削具有很好的润滑冷却作用,可有效延长刀具的使用寿命,两者协同作用可有效改善镍基高温合金的切削性能。
Abstract
Nickel-based superalloy (GH4169) exhibits excellent mechanical properties under high-temperature and high-stress conditions, making it widely used in aerospace and defense industries. However, during milling, the material is prone to high cutting forces and temperatures, leading to rapid tool wear and compromised surface quality of the workpiece. While ultrasonic vibration can mitigate these issues to some extent. Its inherent limitations in lubrication and cooling make it insufficient for effective interfacial lubrication and heat dissipation. To address these challenges, this study proposes a milling method combining Minimum Quantity Lubrication (MQL) with ultrasonic vibration, thereby improving lubrication conditions. The research systematically investigates the mechanism and effectiveness of this technique in achieving high-efficiency, high-quality machining of nickel-based superalloy through three aspects: capillary lubrication permeation mechanism, thermodynamic simulation analysis, and milling experimental validation. The main contributions are as follows:
Based on the capillary action theory of the tool-chip contact zone and the stress distribution, the regular triangular pyramid model and the spatial conditions for cooling lubricant entering the capillary tube are proposed. The penetration and lubrication mechanisms of cutting fluid on the tool are described, a regular triangular pyramid capillary tube model is established, and dynamic analysis is conducted. Friction is incorporated into the analysis to study the lubrication and cooling effects of minimal lubricant in the tool-chip contact zone. The capillary phenomenon of the regular triangular pyramid is further revealed through the wear morphology characteristics on the rake face of the tool.
By establishing interface friction models, heat conduction models, and constitutive models, a thermodynamic analysis of milling nickel-based superalloy is conducted, and a three-dimensional thermal-mechanical coupling finite element model is constructed. The influence of minimal quantity lubrication parameters, including friction coefficients and thermal conductivity, on milling forces and temperatures is systematically analyzed. Additionally, the effect of milling speed, feed per tooth, ultrasonic amplitude, and radial depth of cut on milling forces and temperatures is investigated. It is revealed that ultrasonic vibration effectively reduces tool-chip interface friction and contact time through periodic contact-separation, while minimal quantity lubrication further enhances cooling and friction-reducing effects, significantly improving both cutting forces and temperature distribution.
An experimental system for micro-irrigation-assisted ultrasonic milling is constructed, and process experiments are conducted using nickel-based superalloy materials. Utilizing detection equipment such as dynamometers and infrared thermal imagers, the influence mechanisms of core process parameters including milling speed, feed per tooth, ultrasonic amplitude, and radial depth of cut-on milling forces and temperatures are thoroughly investigated. Experimental results show that under composite machining conditions, GH4169 milling force is reduced by 20%-35% compared with dry cutting. When the ultrasonic amplitude increases from 0 to 3 μm, milling force drops from about 60 N to 50 N, and the maximum cutting temperature decreases by up to 14.8%. The simulation and experimental results well coincide, fully verifying the accuracy and reliability of the simulation model. The research confirms that MQL lubrication and ultrasonic dynamic cutting show significant synergistic effects, effectively compensating for the shortcomings of single processes, significantly reducing tool-chip interface friction, suppressing cutting temperature rise, slowing tool wear, and improving workpiece surface quality. The composite machining method and microscale mechanisms proposed in this paper effectively improve the theory of vibratory lubrication composite machining of superalloys, providing new technical ideas and theoretical support for efficient, green, and low-damage precision milling of nickel-based superalloys.
关键词
MQL超声振动铣削 /
镍基高温合金 /
毛细管 /
铣削力 /
铣削温度
Key words
MQL ultrasonic vibration milling /
nickel-based superalloy /
capillary /
milling force /
milling temperature
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基金
吉林省自然科学基金（YDZJ202401559ZYTS）; 吉林省青年科技人才培养项目（20250602047RC）
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