Experimental study on end face grinding stability of thin-walled CFRP circular cell
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摘要: 针对阵列复合材料管加工中的磨削稳定性问题，以单个薄壁CFRP管为研究对象，结合其结构特征定义切出角度和磨削作用角，开展端面磨削加工实验，分析切出角度对磨削稳定性的影响规律，并基于磨削作用角和切出角度之间的关系，进一步分析磨削速度、实际进给率、磨削深度对磨削稳定性的影响规律。结果表明：切出角度是影响磨削稳定性的主要因素，当切出角度为60°～90°时，磨削作用角较小，磨削稳定性较差；随着磨削速度的增大，磨削作用角逐渐增大，磨削稳定性呈增强的趋势；随着实际进给率的增大，磨削作用角无明显变化，磨削稳定性呈先减弱后几乎不变的趋势；随着磨削深度的增大，磨削作用角逐渐减小，磨削稳定性呈减弱的趋势。Abstract:
Objectives CFRP circular cell honeycomb consists of thin-walled circular cells and are applied in the aerospace. It is difficult to machine the CFRP honeycomb due to its characteristics of thin walls, weak rigidity and non-continuous periodicity. During grinding, there are sharp noises and intense fluctuations of grinding force, reflecting the instability of the process. Considering the structural characteristics of thin-walled CFRP circular cells, this paper conducts end-face grinding experiments and explores the influence of the exit angle, grinding speed, feed rate, and grinding depth on grinding stability. Methods The machining of CFRP honeycomb is a repetition of machining thin-walled CFRP circular cells. Taking a single cell as the research object, the end-face grinding experiment is carried out by defining the exit angle and the interaction angle of grinding based on its structural characteristics. The influence of the exit angle on grinding stability is analyzed using the time-domain and frequency-domain characteristics of the axial force. The standard deviation of the resultant force in the horizontal plane is used to quantitatively describe the grinding stability of the thin-walled CFRP circular cell. Moreover, the influence of the exit angle on the interaction angle of grinding is analyzed based on the magnitudes of the tangential and the radial forces. The relationship between the interaction angle of grinding and the grinding stability is established to analyze the influence of grinding speed, feed rate and grinding depth on the interaction angle of grinding and the grinding stability. Furthermore, the influence of processing parameters on the radial, the tangential and the resultant forces in the horizontal plane is studied. Results It is found that the exit angle is the main factor affecting the grinding stability. Compared with other exit angles, when the exit angle is 60° − 90°, the fluctuation range of the axial force in the time domain increases dramatically and a significant peak appears in the frequency domain. The standard deviation of the resultant force in the horizontal plane increases sharply. The interaction angle of grinding is small, and the direction of the resultant grinding force is close to the tangential direction of the thin-walled CFRP circular cell, resulting in poor grinding stability. The interaction angle of grinding increases linearly with the increase of the exit angle, which strengthens the grinding stability. With the increase of grinding speed, the interaction angle of grinding increases gradually, and grinding stability improves. With the increase of feed rate, the interaction angle of grinding shows no obvious change, and the grinding stability remains nearly unchanged after an initial decrease. With increasing grinding depth, the interaction angle of grinding decreases gradually, and the grinding stability declines. In terms of grinding force, with increasing exit angle, the radial force and the resultant force in the horizontal plane first decrease and then increase, while the tangential force decreases. With increasing grinding speed, the tangential force and resultant force in the horizontal plane gradually decrease, though the overall change range is small, and the radial force shows no obvious change. With increased feed rate and grinding depth, the radial force, tangential force, and resultant force in the horizontal plane increase approximately linearly. Conclusions For thin-walled and weakly rigid CFRP circular cell honeycomb, grinding stability is significantly affected by machining parameters. This paper investigates the influence of machining parameters on grinding stability through end-face grinding experiments of CFRP circular cells and reveals the relationship between the interaction angle of grinding and grinding stability. To enhance grinding stability of the CFRP circular cell honeycomb, the exit angle should avoid the range of 60° − 90°, and a larger grinding speed should be used with a smaller feed rate and grinding depth. -
Key words:
- CFRP /
- end face grinding /
- thin wall weak stiffness /
- grinding stability
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图 5 不同切出角度下轴向力时域及频域变化
Figure 5. Time domain and frequency domain diagram of axial force at different exit angles
图 6 切出角度对磨削力、磨削作用角及合力标准差的影响
Figure 6. Effect of exit angle on grinding force, interaction angle of grinding and resultant standard deviation
图 7 磨削速度对磨削力、磨削作用角及合力标准差的影响
Figure 7. Effect of grinding speed on grinding force, interaction angle of grinding and resultant standard deviation
图 8 实际进给率对磨削力、磨削作用角及合力标准差的影响
Figure 8. Effect of real feed rate on grinding force, interaction angle of grinding and resultant standard deviation
图 9 磨削深度对磨削力、磨削作用角及合力标准差的影响
Figure 9. Effect of grinding depth on grinding force, interaction angle of grinding and resultant standard deviation
表 1 CFRP管预浸料参数表
Table 1. Parameters of CFRP circular cell prepreg
参数 数值 纤维面密度 ρ1 / (g·m−2) 75 树脂体积分数 φ1 / % 38 预浸料面密度 ρ2 / (g·m−2) 121 单层厚度 l / mm 0.075 
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表 2 CFRP管端面磨削加工实验参数表
Table 2. Experimental Parameters of end face grinding for CFRP circular cell
组别 切出角度
φ / (°)磨削速度
vc / (m·s−1)实际进给率
r / (mm·r−1)磨削深度
ap / mm1 10、30、50、70、90、
110、130、1508.38 0.2 2.0 2 70 4.19、6.28、
8.38、10.470.2 2.0 3 70 8.38 0.3、0.4、0.5 2.0 4 70 8.38 0.2 0.5、1.0、3.0
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