增材镍钛合金的微量润滑微铣削表面完整性与刀具磨损研究

    Surface integrity and tool wear in minimum quantity lubrication-assisted micro-milling of additively manufactured NiTi alloys

    • 摘要: 针对增材镍钛合金微铣削存在的表面质量差、加工硬化明显、刀具磨损严重问题,采用激光粉末床熔融工艺制备增材镍钛合金试样,开展干式与微量润滑条件下的对比微铣削实验,探究切削参数对表面完整性及刀具磨损的影响规律,并结合切削表面表征分析微量润滑的改善机制。结果表明:干式微铣削条件下,增材镍钛合金受耕犁效应和刀具黏附磨损共同作用,表面易出现撕裂、深沟等缺陷。与干式条件相比,微量润滑使表面粗糙度平均下降约30.1%,加工表面显微硬度平均下降约8.9%,毛刺高度和毛刺宽度分别下降34.4%和50.2%,刀具磨损由严重的崩刃与前后刀面磨损变为轻微刃口钝化。微量润滑通过降低刀具-工件界面摩擦、抑制热积聚并改善排屑条件,促使材料去除机制由耕犁主导向稳定剪切主导转变,从而显著改善增材镍钛合金微铣削表面完整性并降低刀具磨损。

       

      Abstract: NiTi alloys possess excellent shape memory properties and superelasticity, demonstrating significant value in applications such as aerospace and medical devices. To address the problems of poor surface quality, pronounced work hardening, and severe tool wear in the micro-milling of additively manufactured NiTi alloys, specimens were fabricated by laser powder bed fusion (LPBF), and comparative micro-milling experiments were conducted under dry and minimum quantity lubrication (MQL) conditions. The effects of cutting parameters on surface integrity and tool wear were investigated, and the improvement mechanism of MQL was analyzed in combination with machined surface characterization. The results show that, under dry micro-milling conditions, the combined effects of ploughing and adhesive tool wear tend to cause defects such as surface tearing and deep grooves on the machined surface. Compared with dry cutting, MQL reduced the average surface roughness by approximately 30.1% and the average surface microhardness by approximately 8.9%, while burr height and burr width decreased by 34.4% and 50.2%, respectively. In addition, tool wear changed from severe edge chipping and rake/flank wear to slight cutting-edge blunting. By reducing friction at the tool-workpiece interface, suppressing heat accumulation, and improving chip evacuation, MQL promotes a transition in the material removal mechanism from ploughing-dominated removal to stable shear-dominated removal, thereby significantly improving surface integrity and reducing tool wear in the micro-milling of additively manufactured NiTi alloys.

       

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