ϕ0.75 mm深小孔微镗削切削三要素优化分析

Optimization analysis of the three essential factors in micro-boring of ϕ0.75 mm deep small holes

  • 摘要: 由05Cr17Ni4Cu4Nb不锈钢材料制造的活门座,其上的深小孔(直径为0.75 mm,深为4 mm)是用来控制燃油流量的重要结构,质量要求严格。针对现有切削三要素选择不合理,导致加工深小孔孔口时有时会出现孔口圆度不符合设计要求和孔口切入处破损的问题。文章采用单因素试验法和正交试验法,研究了切削三要素对切削力的影响规律,并选取最合适的切削参数组合,最后通过试验验证了优化效果。结果表明,切削力随背吃刀量、进给量、主轴转速的增大而增大,对切削力的影响主次顺序为进给量>背吃刀量>主轴转速;最优切削三要素组合为背吃刀量为0.010 mm、进给量为0.003 mm/r、主轴转速为750 r/min;使用微型三轴加速度传感器,对优化前后的切削参数进行加工深小孔的试验,与优化前相比,优化后的切削参数加工深小孔面时,刀具轴向加速度降低了43.55%,径向加速度降低了41.95%,切向加速度降低了46.51%,有效降低了刀具的颤振,孔口加工质量明显提高。

     

    Abstract: The valve seat made of 05Cr17Ni4Cu4Nb stainless steel material features a deep small hole (diameter 0.75 mm, depth 4 mm) that serves as a critical structure for controlling fuel flow, with stringent quality requirements. Addressing the issue of inappropriate selection of the existing cutting parameters, which sometimes leads to non-compliance with the design requirements for the roundness of the hole mouth and damage at the entry point of the hole mouth during the machining of deep small holes, this paper employs single-factor experimental and orthogonal experimental methods to study the influence of the cutting parameters on cutting force, selects the most suitable combination of cutting parameters, and finally verifies the optimization effect through experiments. The results indicate that the cutting force increases with the increase of depth of cut, feed rate, and spindle speed. The order of influence on cutting force is feed rate > depth of cut > spindle speed. The optimal combination of cutting parameters is a depth of cut of 0.010 mm, a feed rate of 0.003 mm/r, and a spindle speed of 750 r/min. Using a miniature triaxial acceleration sensor, experiments were conducted to process deep small holes with optimized and non-optimized cutting parameters. Compared with the non-optimized parameters, the optimized cutting parameters resulted in a 43.55% reduction in axial acceleration, a 41.95% reduction in radial acceleration, and a 46.51% reduction in tangential acceleration of the tool, effectively reducing tool chatter and significantly improving the machining quality of the hole entrance.

     

/

返回文章
返回