Precision hole-machining of SiCf/SiC composite using single-layer brazed diamond core drill dressed by pulsed laser
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摘要: 单层钎焊金刚石套料钻工作面磨粒的出露高度差异大、等高性难以保证，导致SiCf/SiC复合材料制孔时孔径精度难控制。针对此瓶颈，提出采用脉冲激光修整单层钎焊金刚石套料钻工作面磨粒，提高磨粒等高性以改善SiCf/SiC复合材料制孔精度的构想。研制单层钎焊金刚石套料钻的脉冲激光修整装置，能够显著提高套料钻工作面磨粒的等高性，修整后套料钻磨粒出露高度离散系数由修整前的0.11降低至0.04，降幅达64%。此外，修整后的套料钻在有效使用寿命范围内的孔径变化量维持在0.02 mm以内，相较未激光整形时孔径变化量降低75%，说明激光修整可提高单层钎焊金刚石套料钻工作面磨粒的等高性，实现SiCf/SiC复合材料精密制孔。
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关键词:
- 单层钎焊金刚石套料钻 /
- SiCf/SiC复合材料 /
- 激光修整 /
- 孔径精度 /
- 超声振动辅助加工
Abstract:Objectives The single-layer brazed diamond core drill generally exhibits poor protrusion height uniformity of grains, making it difficult to control the hole diameter and the accuracy when machining SiCf/SiC composites. Pulsed laser is used to dress the core drill to improve grain height uniformity, thereby enhancing hole accuracy on SiCf/SiC composite. Methods Firstly, a pulsed laser dressing platform for the single-layer brazed diamond core drill is developed, and the influence of laser dressing parameters on grain height uniformity and morphology is revealed. Then, the aperture accuracy of the core drill before and after dressing is compared and analyzed to verify the benefits of laser dressing in improving hole accuracy. Finally, high-quality processing of SiCf/SiC composite holes is achieved using the dressed drill. During the process, the total cutting depth of the pulsed laser is determined by dressing a standard rod to the target aperture size and then replacing it with the core drill for further dressing. The relative distance between the abrasive grains and the laser beam is adjusted, and the laser beam focus is aligned with the cutting point. The laser beam is reciprocally scanned along the tool axis to remove the protruding diamond grains and improve core drill height uniformity. Results The experiments show that pulsed laser dressing can effectively enhance the height uniformity of the side grains on the single-layer brazed diamond core drill. The discrete coefficient of grain height after dressing is reduced by 64%, from 0.11 to 0.04. Following pulsed laser dressing, the contour lines of side grains on the core drill become smoother, indicating improved height uniformity. The surface of diamond grains after pulsed laser ablation appears black due to a graphitization reaction, forming a thin black metamorphic layer that does not affect diamond grain performance. The laser-dressed single-layer brazed diamond core drill exhibits improved hole-making performance with a smaller variation range in hole diameter (4.00 - 4.02 mm) and higher hole-making accuracy. In contrast, the untrimmed core drill shows a larger variation range in hole diameter (4.06 - 3.98 mm) during the hole-making process. Furthermore, pulsed laser dressing has no negative impact on the grinding ability of the core drill. The average drilling force is 13.72 N before dressing and 12.43 N after dressing, with a difference of 1.29 N consistent with the change trend of the drilling force during the entry stage. The laser-dressed core drill maintains aperture accuracy better throughout its lifespan, with aperture deviation being only 0.02 mm, meeting the requirements on hole accuracy and showing a 75% reduction compared to the undressed condition. Conclusions The study applies pulsed laser dressing to enhance the protrusion height uniformity of grains on single-layer brazed diamond core drills. A laser dressing device is constructed, and a method is proposed. Using a graphite rod as the standard rod for determining the laser dressing depth reduces the diameter deviation. Pulsed laser dressing effectively improves grain height uniformity, with the discrete coefficient reduced by 64%. The dressed core drill demonstrates smaller aperture deviation (0.02 mm), meeting accuracy requirements without adversely affecting grinding ability or service life. This verifies the advantage of laser-dressed core drills in improving hole-making accuracy. -
图 9 钎焊金刚石套料钻激光修整过程及原理
Figure 9. Laser dressing process and schematic diagram of brazed diamond core drill
图 8 2种不同材质标准棒修整效果对比
Figure 8. Comparison of dressing effects of two standard rods made of different materials
图 10 脉冲激光修整前后钎焊金刚石套料钻轮廓线
Figure 10. Contour of brazed diamond core drill before and after laser dressing
图 11 修整前后侧边磨粒实际高度图
Figure 11. Grain protrusion height before and after pulsed laser dressing
图 12 激光整形后钎焊金刚石套料钻磨粒形貌
Figure 12. Diamond grits morphology of brazed diamond core drill after pulsed laser dressing
图 13 激光修整前后单层钎焊金刚石套料钻制孔直径变化
Figure 13. Diameter of holes machined by single-layer brazed diamond core drill before and after pulsed laser dressing
图 14 单层钎焊金刚石套料钻制孔过程
Figure 14. Drilling process of single-layer brazed diamond core drill
图 15 脉冲激光修整前后钻削力信号
Figure 15. Signals of drilling force before and after pulse laser dressing
表 1 SiCf/SiC复合材料机械属性
Table 1. Mechanical properties of SiCf/SiC composites
材料 密度
ρ / (g·cm−3)弹性模量
E / GPa硬度
H / GPa断裂韧性
Kic / (MPa·m1/2)SiCf/SiC 2.0 289 23 26.4 
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表 2 脉冲激光修整钎焊金刚石套料钻参数
Table 2. Parameters of pulsed laser dressing of brazed diamond core drill
参数 数值 参数 数值 聚焦距离 s / mm 0 光斑直径 df / μm 40 平均功率 pavg / W 50 脉宽 ω / ns 120 脉冲频率 fp / kHz 50 往复扫描次数 Nz / 次 100 扫描速度 vss / (mm·s−1) 400 旋转主轴转速 vsx / (r·min−1) 120
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表 3 套料钻磨粒高度离散度分析
Table 3. Dispersion of grain protrusion height
项目 修整前 修整后 平均磨粒高度 $\bar H $ / mm 361.5 328.4 方差 s2 1587.6 153.1 标准差 s 39.8 12.4 离散系数 Vs 0.11 0.04
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