Numerical simulation and experimental study of ultrasonic machining of aluminum honeycomb core
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摘要: 铝蜂窝在使用传统加工技术加工时容易受损。为提高铝蜂窝加工表面质量，建立铝蜂窝超声加工切削力数学模型和仿真计算模型，研究网格尺寸对仿真结果的影响，确定合适的网格尺寸，并分析不同加工参数下的切削力和表面形貌。综合评价后选用0.2 mm的网格进行仿真模拟，结果表明随着进给量、主轴转速和切削宽度数值分别增大，加工损伤明显呈下降趋势。研究结果为铝蜂窝超声辅助加工的数值模型、仿真和试验提供了基础。Abstract: Traditional machining techniques often result in damage to the aluminum honeycomb. In order to improve the surface quality of aluminum honeycomb machining, the numerical and simulation models of cutting force in ultrasonic-assisted machining of aluminum honeycomb were established. The influence of mesh size on simulation results was investigated to determine an appropriate mesh size. Furthermore the cutting forces and surface morphology were analyzed for different machining parameters. After a thorough evaluation, a mesh of 0.2 mm was chosen for the simulation. The results show that there is a clear reduction in machining damage with increasing the feed rate, spindle speed, and cutting width values. This conclusion can provide reference for mathematical model, simulation and experiment of ultrasonic-assisted machining of aluminum honeycomb.
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Key words:
- aluminum honeycomb /
- ultrasonic machining /
- surface quality /
- machining parameters
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图 3 蜂窝芯超声切削局部示意图
Figure 3. Local cutting process of ultrasonic machining of honeycomb core
图 8 0.5 mm网格时蜂窝芯超声切削力仿真
Figure 8. Ultrasonic simulation of aluminum honeycomb core with a mesh size of 0.5 mm
图 9 网格尺寸为0.1~0.4 mm时切削力分量
Figure 9. Cutting force components of ultrasonic simulation with a mesh size between 0.1 to 0.4 mm
图 12 不同进给量下的应力云图、切削力和表面形貌
Figure 12. Stress nephogram, cutting force and surface morphology under different feed rates
图 13 不同主轴转速下的应力云图、切削力和表面形貌
Figure 13. Stress nephogram, cutting force and surface morphology under different spindle speeds
图 14 不同切削宽度下的应力云图、切削力和表面形貌
Figure 14. Stress nephogram, cutting force and surface morphology under different cutting widths
表 1 蜂窝细胞结构参数
Table 1. Structure parameters of aluminum honeycomb core
蜂窝细胞结构参数 数值 细胞尺寸c/mm 4.7 单层细胞厚度t/mm 0.0 细胞边长a/mm 1.37 细胞边长b/mm 1.37 胞壁角度$ \mathrm{\phi } $/(°) 120 
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表 2 Al5052的力学性能
Table 2. Mechanical properties of Al5052
属性 符号 单位 数值 密度 $ \rho $ ${\rm{kg}}/{{\rm{m}}}^{3}$ 2680 弹性模量 — ${\rm{GPa}}$ 70.3 泊松比 — — 0.33 比热 — J/(kg·℃ ) 930 参考温度 ${T}_{{\rm{r}}}$ ${\rm{K}}$ 293 熔化温度 ${T}_{{\rm{m}}}$ ${\rm{K}}$ 903 屈服应力 $ A $ ${\rm{MPa}}$ 92.4 硬化模量 $ B $ ${\rm{MPa}}$ 132 应变率敏感常数 $ C $ — 0.02511 参考应变率 $ {\dot{\stackrel{-}{\varepsilon }}}_{0} $ ${{\rm{s}}}^{-1}$ 1 硬化指数 $ n $ — 0.25 热软化指数 $ m $ — 1
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表 3 Al5052的损伤参数
Table 3. Damage parameters of Al5052
参数 $ {D}_{1} $ $ {D}_{2} $ $ {D}_{3} $ $ {D}_{4} $ $ {D}_{5} $ 数值 0.306 0.0446 −1.72 0.0056 0.0
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表 4 单因素试验参数
Table 4. Machining parameters for single-factor experiments
变量 水平 进给速度f/(mm·min−1) 500, 1000 ,1500 ,2000 主轴转速n/(r·min−1) 500,600,700,800 切削宽度ae/mm 4,6,8,10
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表 5 不同网格尺寸的仿真耗时
Table 5. Simulation time consumption of different mesh sizes
网格尺寸/mm 耗时/h 0.1 23.50 0.2 2.50 0.3 2.01 0.4 1.09 0.5 0.85
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