基于电致塑性效应的电脉冲辅助钛合金切削加工机理研究

High strength, low heat transfer coefficient, high chemical reactivity of titanium alloy made cutting temperature high, tool wear severe in machining process, which resulted in high processing cost and low efficiency of titanium alloy parts in the aviation and military industries. The project made use of electroplastic effect to change the machinability of metal materials, and proposed the research on electropulsing assisted titanium alloy machining mechanisms based on electroplastic effect. (1) The machining process of titanium alloy under thermal effect of electropulsing was performed with numerical simulation, the experiment of the non-thermal effect influence in the electropulsing assisted machining process was combined, the influences of the thermal and non-thermal effects on the machinability were revealed, respectively. (2) The influence of the coupling effect of the thermal and non-thermal effects on tool-chip friction pairs, tool wear, chip morphology and workpiece surface integrity was studied, the titanium alloy electropulsing machining mechanisms were mastered. (3) Quantitative relationship of electropulsing parameters and cutting parameters with cutting forces and workpiece surface roughness was studied to carry out the combinatorial optimization design of electropulsing and cutting parameters, the electropulsing assisted machinability was evaluated. The aim of the project was to develop a new method for the cutting process of titanium alloy, the research had important theoretical significance and engineering value to enrich the machining theory and improve the machinability of titanium alloy.

由于钛合金的强度高、传热系数小、化学活性高使其切削加工过程中的切削温度高、刀具磨损严重，造成航空、军工等领域钛合金零件的加工成本高、效率低。项目利用电致塑性效应能改变金属材料的切削加工性能，提出基于电致塑性效应的电脉冲辅助钛合金切削加工机理研究。(1)对电脉冲热效应下钛合金的切削加工进行有限元模拟，结合电脉冲辅助切削过程中非热效应的影响实验，揭示电脉冲热效应与非热效应对切削加工性能的影响规律；(2)研究电脉冲热效应与非热效应的耦合作用对刀屑摩擦、刀具磨损、切屑形貌和工件表面完整性的影响，获悉钛合金电致塑性效应切削加工机理；(3)研究电脉冲参数、切削参数对切削力和工件表面粗糙度的定量关系，进行电脉冲、切削参数的组合优化设计，并实施对电脉冲辅助切削加工性能的评估。项目旨在为钛合金切削加工工艺另辟蹊径，对于丰富钛合金的切削加工理论和改善钛合金材料的切削加工性能，具有重要的理论意义与工程价值。

钛合金材料的高强度、低密度和高生物相容性，使其被广泛应用到航空、军工和医学等领域。钛合金零部件多需要经过热处理工序调控微观结构和力学性能，然而传统热处理钛合金的力学性能无法达到使用要求。电脉冲可以在极短时间、较低温度下调控钛合金的微观结构和力学性能，电脉冲处理后的钛合金切削性能发生改变，因此需要进行电脉冲处理的钛合金组织性能及切削机理研究。本项目研究了电脉冲处理对钛合金微观结构、力学性能的影响规律，探索了电脉冲处理对钛合金切削性能的影响机制。项目此内容的研究为解决钛合金紧固件力学性能无法达到使用要求提供了解决途径。.钛合金材料具有极其恶劣的难加工性，冷却介质、激光辅助等多种方法，均无法明显提高钛合金的切削性能。项目利用电致塑性效应能改变金属材料的切削加工性能，提出基于电致塑性效应的电脉冲辅助钛合金切削加工机理研究。探索了电脉冲参数对切削力、切削温度、刀具磨损、切屑形貌和工件表面质量的影响，揭示了电脉冲辅助钛合金切削机理，提出电脉冲辅助钛合金切削能够明显改善刀具的粘刀磨损。项目此内容的研究为钛合金的切削提供新的方法。.在项目的资助下，国内外重点期刊上正式发表论文4篇，其中EI收录1篇、CSCD核心1篇；申请国家发明专利2项；申请实用新型专利4项，授权3项；申请软件著作权1项。