| WANG Guangyu,JIN Gang,LI Zhanjie,TAN Hui,ZHAN Qiyun,LIN Huaixin,WANG Xiaoran.Ultra-precision Turning Process of 6061 Aluminum Alloy Based on Multi-objective Optimization of Surface Roughness and Reflectivity[J],53(12):193-206 |
| Ultra-precision Turning Process of 6061 Aluminum Alloy Based on Multi-objective Optimization of Surface Roughness and Reflectivity |
| Received:August 20, 2023 Revised:November 16, 2023 |
| View Full Text View/Add Comment Download reader |
| DOI：10.16490/j.cnki.issn.1001-3660.2024.12.016 |
| KeyWord:single-point diamond turning 6061 aluminum alloy orthogonal test surface roughness surface optical reflectivity grey correlation analysis |
| Author | Institution |
| WANG Guangyu |
School of Mechanical Engineering, Tianjin University of Technology and Education, Tianjin , China;Tianjin Key Laboratory of High Speed Cutting and Precision Processing, Tianjin , China |
| JIN Gang |
School of Mechanical Engineering, Tianjin University of Technology and Education, Tianjin , China;Tianjin Key Laboratory of High Speed Cutting and Precision Processing, Tianjin , China |
| LI Zhanjie |
School of Mechanical Engineering, Tianjin University of Technology and Education, Tianjin , China;Tianjin Key Laboratory of High Speed Cutting and Precision Processing, Tianjin , China |
| TAN Hui |
School of Mechanical Engineering, Tianjin University of Technology and Education, Tianjin , China;Tianjin Key Laboratory of High Speed Cutting and Precision Processing, Tianjin , China |
| ZHAN Qiyun |
School of Mechanical Engineering, Tianjin University of Technology and Education, Tianjin , China;Tianjin Key Laboratory of High Speed Cutting and Precision Processing, Tianjin , China |
| LIN Huaixin |
School of Mechanical Engineering, Tianjin University of Technology and Education, Tianjin , China;Tianjin Key Laboratory of High Speed Cutting and Precision Processing, Tianjin , China |
| WANG Xiaoran |
Tianjin Aerospace Institute of Electrical and Mechanical Equipment, Tianjin , China |
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| Abstract: |
| Single point diamond turning (SPDT) is currently an important technology in the field of ultra-precision machining, mostly used in the manufacture of high-precision optical components. The 6061 aluminum alloy combined with SPDT technology, can be directly used for the optical system to create a high level of metal mirrors. Since the surface machining accuracy and surface optical properties in single-point diamond ultra-precision turning technology are affected by many factors, it is necessary to analyze the effect of process parameters on the surface roughness and optical properties of the material after ultra-precision turning. The work aims to explore the effect of process parameters on the ultra-precision turning performance of rolled 6061 aluminum alloy parts, and carry out a synergistic optimization study on the surface roughness and surface optical reflectivity of the workpiece ultra-precision turning process. First of all, the surface of 6061 aluminum alloy material was subject to one-way ultrasonic vibration rolling to improve the surface quality of the workpiece. The surface of the material was subject to the joint effect of the spindle speed of the rolling head, feed speed and high-frequency ultrasonic impact amplitude, and the preparation of test pieces by ultrasonic rolling before ultra-precision turning laid a good foundation for the subsequent ultra-precision turning test. Then, a 4-factor, 4-level orthogonal test of ultra-precision turning was designed to investigate the effect of cutting process parameters (spindle speed, feed rate, back-eating amount, and tip radius) on the surface roughness and surface optical reflectivity of rolled 6061 aluminum alloy parts. In addition, the interconnection between surface roughness and surface reflectivity was explored. Finally, the grey correlation analysis method was adopted to transform multiple process objective parameter optimization problems into single-objective grey correlation degree optimization problems, and the optimization results were verified through the ultra-precision turning test. By comparing the surface roughness Sa and the visible VIS reflectance trend, it could be seen that the roughness value and the surface reflectance had a negative correlation, i.e., an increase in surface roughness corresponding to a decrease in the surface reflectivity of the material. However, this negative correlation was not obvious when the trends of surface roughness Ra and VIS reflectivity were compared. The spindle speed had the most significant effect on the surface roughness Ra and Sa, followed by the tool tip radius and the amount of back draft, and the feed speed had the least effect. The degree of effect of process parameters on the reflectivity of the visible and mid-infrared bands was the same as that of the surface roughness, and the degree of effect on the reflectivity of the near-infrared bands was as follows:the amount of back draft > the tool tip radius > the feed speed > the spindle speed. The optimized process parameters were obtained through the grey correlation analysis. The optimized process parameters were spindle speed of 3 000 r/min, feed speed of 10 mm/min, back draft of 5 μm, and tip radius of 0.5 mm, at which the corresponding surface roughness Ra and Sa were 2.162 nm and 7.855 nm, and the reflectivity of visible, near-infrared, and mid-infrared wavelengths were 88.892%, 88.893%, and 97.788%, respectively. The optimization results can effectively reduce the surface roughness and improve the surface optical reflectivity, which is of great practical significance and research value for manufacturing high-level metal mirrors. |
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