铝合金叠层板钻削层间毛刺高度预测模型
Predictive model for the interlayer burr height during drilling of stacked aluminum plates

叠层构件制孔容易生成层间毛刺，严重影响加工质量和效率。为了探究层间毛刺生成过程，预测毛刺高度，提出有效控制层间毛刺的工艺方法，该文首先通过实验建立钻削轴向力经验公式，然后采用有限元方法计算单层板在理论钻削力下的变形量，进而预测层间毛刺生成初始位置，最后运用能量法建立叠层钻削层间毛刺高度理论模型。应用硬质合金麻花钻在铝合金叠层试件上开展钻削实验，结果表明：理论模型能够有效地预测层间毛刺高度，揭示进给量和层间间隙对层间毛刺的影响规律，有助于优化叠层钻削工艺参数。
Abstract：The drilling of stacked components tends to form interlayer burrs, which reduce machining quality and the production efficiency. This study analyzes the formation and height of interlayer burrs and presents an effective processing method to control interlayer burrs. An empirical formula was developed for the thrust force during drilling for an finite element analysis (FEA) model of the drilling process to product the single plate deformations and to find the initial burr formation position. Then, the energy method is used in a mechanical model to product the interlayer burr height. The predictions agree well with drilling experiments with stacked aluminum plates and a carbide drill. The results show the effects of the feed rate and the interlayer gap on the interlayer burr formation to optimize the processing parameters of stacked components.