基于表层改性与微织构技术协同调控的TC4加工表面质量研究

佟欣; 王佰艺; 杨树财; 刘峰; 张金炜

doi:10.16490/j.cnki.issn.1001-3660.2026.16.005

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表面技术 ›› 2026, Vol. 55 ›› Issue (16) : 54-65. DOI: 10.16490/j.cnki.issn.1001-3660.2026.16.005

专题——难加工材料精密加工

基于表层改性与微织构技术协同调控的TC4加工表面质量研究

佟欣, 王佰艺, 杨树财^*, 刘峰, 张金炜

作者信息 +

Surface Quality of TC4 Machining Based on Synergistic Regulation by Surface Modification and Micro-texture Technology

TONG Xin, WANG Baiyi, YANG Shucai^*, LIU Feng, ZHANG Jinwei

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文章历史 +

摘要

目的针对TC4钛合金球头铣刀铣削过程中界面黏附强、切削载荷大和加工表面质量不稳定等问题,提出工件表层改性与微织构球头铣刀协同调控切削界面状态的方法,以提高TC4钛合金铣削过程稳定性和加工表面质量。方法采用化学介质改性、脉冲离子渗硫改性和活性介质涂敷改性调控TC4钛合金表层状态,结合SEM、EDS表征和铣削力测试分析不同改性方式对切削界面的影响;在此基础上,以石墨烯涂敷改性TC4为加工对象,设计微织构球头铣刀铣削试验,研究织构直径、织构间距、激光功率、扫描速度和扫描次数对加工表面质量的影响。结果未改性TC4钛合金的75次加工平均铣削力为162.54 N;化学介质改性和脉冲离子渗硫改性均可降低铣削力,平均铣削力分别降至145.25和143.73 N,降幅分别为10.64%和11.57%;其中,石墨烯涂敷改性试样铣削力最低,平均值为140.17 N,较未改性试样降低了13.76%;微织构球头铣刀与石墨烯涂敷改性层协同铣削后,在所选参数范围内工件表面粗糙度最低降至0.279 μm。结论工件表层改性可削弱刀具-工件界面的黏附和摩擦阻力,刀具微织构可进一步改善刀-屑接触状态;二者协同作用能够有效改善TC4钛合金球头铣刀铣削表面质量。

Abstract

TC4 titanium alloy is widely used in high-end manufacturing fields such as aerospace and marine equipment due to its low density, high specific strength and excellent corrosion resistance. However, the material features low thermal conductivity and strong chemical activity. When machined by ball-end milling cutters, severe tool-workpiece interfacial adhesion, high cutting loads, obvious machining vibration and unstable surface quality frequently occur, which greatly restricts its high-efficiency and precision machining. To address the above processing challenges, the work aims to propose a synergistic regulation method combining workpiece surface modification and micro-textured ball-end milling cutters. By optimizing the friction, adhesion and contact state of the cutting interface from both the workpiece substrate and cutting tool sides, the milling stability and machined surface quality of TC4 titanium alloy were effectively improved. Three surface treatment processes, namely chemical medium modification, pulsed ion sulfurization modification and active medium coating modification, were adopted to treat TC4 titanium alloy. Scanning electron microscopy (SEM) and energy-dispersive X-ray spectroscopy (EDS) were employed to characterize the microscopic morphology and elemental distribution of different modified layers. Combined with 75 consecutive milling force tests, the effects of various modification methods on cutting interface behaviors and the evolution of milling force were systematically investigated. The experimental results showed that the average milling force of unmodified TC4 titanium alloy after 75 machining cycles was 162.54 N. After chemical medium modification and pulsed ion sulfurization modification, micron-scale corrosion pits and sulfur-rich lubricating layers were formed on the workpiece surface respectively. The average milling forces decreased to 145.25 N and 143.73 N, with reduction rates of 10.64% and 11.57% in comparison with the base material. Through graphene coating modification, a continuous two-dimensional layered lubricating film formed on the titanium alloy surface, which isolated the direct contact between tool and workpiece and delivered outstanding friction reduction via interlayer sliding. It achieved the optimal force reduction effect, with an average milling force of only 140.17 N and a reduction of 13.76% relative to the unmodified specimens. On the basis of the optimized graphene-coated workpieces, orthogonal milling tests were carried out with micro-textured ball-end milling cutters. The effects of texture diameter, texture spacing, laser power, scanning speed and scanning times on the machined surface quality were emphatically analyzed. The research revealed that the micro-textures on the tool surface could store lubricating medium, accommodate fine wear debris and reduce the contact area between tools and chips, forming a favorable synergistic effect with the graphene modified layer. Within the range of selected parameters in this experiment, the minimum surface roughness of the machined workpiece reached 0.279 μm. Mechanism analysis indicated that workpiece surface modification could effectively weaken interfacial adhesion and reduce frictional resistance between tool and workpiece, while tool micro-textures further optimized the tool-chip contact mode and improved the retention condition of lubricating medium. The synergistic effect of the two technologies can significantly suppress the fluctuation of milling force, alleviate surface scratching and adhesive damage, and comprehensively improve the overall machining performance of TC4 titanium alloy during ball-end milling. This work provides a feasible technical solution and experimental reference for the low-load and high-quality cutting of difficult-to- machine titanium alloys.

导出引用

佟欣, 王佰艺, 杨树财, 刘峰, 张金炜. 基于表层改性与微织构技术协同调控的TC4加工表面质量研究[J]. 表面技术. 2026, 55(16): 54-65

TONG Xin, WANG Baiyi, YANG Shucai, LIU Feng, ZHANG Jinwei. Surface Quality of TC4 Machining Based on Synergistic Regulation by Surface Modification and Micro-texture Technology[J]. Surface Technology. 2026, 55(16): 54-65

中图分类号： TG506 TG714

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