| Fiber Reinforced Plastics(FRP)has the advantages of light weight,high strength,fatigue resistance,corrosion resistance and designable properties,which has been widely used in aviation,transportation,construction and other fields.In the traditional FRP processing mode,the tool is prone to wear and the processing quality is poor.At the same time,the efficiency of FRP processing is low,and the damage of FRP such as delamination,fiber breakage and matrix fragmentation is easily caused in the traditional FRP processing method.A High-speed precision cutting method of fiber reinforced composite materials with ultra-thin diamond grinding blade is proposed in the paper.The effects of different process parameters on the processing quality is studied,which provided a new processing method and basic test parameters for the processing of fiber reinforced composite materials.The research work in the paper is as follows:Firstly,the failure mechanism of fiber reinforced composite materials is analyzed based on the strength theory of fiber reinforced composite materials and the cutting mechanics model of single abrasive particle is established.The cutting model of fiber reinforced composite materials is established combined with the number of effective abrasive particles involved in cutting and the factors affecting the per unit cutting force are obtained.Then,the performance of the tool is analyzed.It is concluded that the most important factor affecting the performance of the tool is the stress and deformation of the tool caused by the centrifugal force produced at high speed rotation of tool,which affects the final surface quality.Taking carbon fiber reinforced composite materials as the test object,the maximum current,cutting temperature and surface quality of spindle motor are analyzed under different fiber laying angles,different types of binder cutting tools and different process parameters.The vibration of spindle is measured and the damage caused by tool vibration under different process parameters is analyzed.The cutting force was studied by single particle abrasive scratch test.The finite element simulation analysis of the single-particle cutting and scratching fiber reinforced composites is carried out.The damage type and cutting force of the material are extracted,and the test results are compared and confirmed.Finally,the optimum technological parameters are obtained.According to the micro-cutting test of fiber diameter,it is found that precision cutting can effectively reduce the processing damage during cutting.The optimum process parameter combination of the unidirectional carbon fiber reinforced composites processing is the spindle speed of 30000r/min,the feed speed of 6mm/s and the depth of cut of 0.3mm,and the optimal surface roughness Ra value is 0.016 ?m.Taking aramid fiber composite materials as the test object,the maximum current value of spindle motor,tool loss,cutting heat and surface quality during tool cutting are analyzed by orthogonal test and verification test.The optimum technological parameters are obtained.According to the micro-cutting test of fiber diameter,it is found that the damage caused by cutting heat can be effectively reduced in the process of micro-cutting.The optimum process parameter combination of the aramid fiber composite materials processing is the spindle speed of 30000r/min,the feed speed of 5mm/s and the depth of cut of 0.2mm,and the optimal surface roughness Ra value is 0.038 ?m.Taking glass fiber reinforced composite materials as the test object,the maximum current value,cutting heat and tool loss of spindle motor in the process of machining are analyzed by multi-factor orthogonal test and verification test.The optimum technological parameters are obtained.The optimum process parameter combination of the glass fiber reinforced composite materials processing is the spindle speed of 30000r/min,the feed speed of 5mm/s and the depth of cut of 0.2mm,and the optimal surface roughness Ra value is 0.131 ?m... |
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