叠层复合材料超声振动辅助螺旋铣削制孔工艺的试验研究

针对某40CrNiMoA/玻璃纤维增强塑料（GFRP）航空叠层复合材料构件连接孔的制孔质量差和加工效率低的问题，提出了超声振动辅助螺旋铣削制孔新工艺。分析了超声振动辅助螺旋铣削制孔方法的刀具运动轨迹，给出了超声振动有效加工的振幅范围，在相同的切削速度与加工效率下，分析比较了3种不同 工艺方法的切削力、切削温度及制孔质量。试验结果表明：相对普通螺旋铣削与钻削，超声振动辅助螺旋铣削加工40CrNiMoA材料时切削力分别降低25%和40%，最高切削温度降低15.7%和22%；加工GFRP材料时，最高切削温度降幅分别为16.5%和50%，且孔出口撕裂、毛刺等缺陷明显减少，达到制造要求。

Drilling Experiment of Laminated Composites by Ultrasonic Vibration Assisted Helical Milling Method

An ultrasonic vibration assisted helical milling method is proposed for machining 40CrNiMoA/glassfiber reinforced plastics (GFRP) laminated composites. The tool trajectory of ultrasonic vibration assisted helical milling method is analyzed, and the ultrasonic vibration amplitude range of effective machining is deduced. The cutting force, cutting temperature and machining quality of three different machining method under the same tool cutting speed and machining efficiency are analyzed. The results show that, compared with the traditional helical milling and drilling，the cutting forces of ultrasonic vibration assisted helical milling of 40CrNiMoA are reduced by 25% and 40%, respectively; while the maximum cutting temperatures are decreased by 15.7% and 22%. When processing GFRP, the maximum temperature is reduced by 16.5% and 50%. Meanwhile, the hole walk surface quality is significantly improved, the manufacturing defects, such as tearing and burrs, are significantly reduced to reach the manufacturing requirements.